Systems and methods for generation of electrical power at a drilling rig

ABSTRACT

Embodiments of systems and methods for generating power in the vicinity of a drilling rig are disclosed. During a drilling operation, heat generated by drilling fluid flowing from a borehole, exhaust from an engine, and/or fluid from an engine&#39;s water (or other fluid) jacket, for example, may be utilized by corresponding heat exchangers to facilitate heat transfer to a working fluid. The heated working fluid may cause an ORC unit to generate electrical power.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims priority to and thebenefit of U.S. Provisional Application No. 63/269,862, filed Mar. 24,2022, titled “Systems and Methods for Generation of Electrical Power ata Drilling Rig,” and U.S. Provisional Application No. 63/269,572, filedMar. 18, 2022, titled “Systems and Methods for Generation of ElectricalPower at a Drilling Rig,” U.S. Provisional Application No. 63/261,601,filed Sep. 24, 2021, titled “Systems and Methods Utilizing GasTemperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. This application also is a continuation-in-part ofU.S. Non-Provisional application Ser. No. 17/305,297, filed Jul. 2,2021, titled “Systems for Generating Geothermal Power in an OrganicRankine Cycle Operation During Hydrocarbon Production Based on WorkingFluid Temperature,” which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. This application further is acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/578,520, filed Jan. 19, 2022, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” which claims priority to and thebenefit of U.S. Provisional Application No. 63/261,601, filed Sep. 24,2021, titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” and U.S. Provisional Application No. 63/200,908, filed Apr. 2,2021, titled “Systems and Methods for Generating Geothermal Power DuringHydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationalso further is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/578,528, filed Jan. 19, 2022, titled “Systemsand Methods Utilizing Gas Temperature as a Power Source,” which claimspriority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. The application still further is acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/578,542, filed Jan. 19, 2022, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” which claims priority to and thebenefit of U.S. Provisional Application No. 63/261,601, filed Sep. 24,2021, titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” and U.S. Provisional Application No. 63/200,908, filed Apr. 2,2021, titled “Systems and Methods for Generating Geothermal Power DuringHydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationadditionally is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/578,550, filed Jan. 19, 2022, titled “Systemsand Methods Utilizing Gas Temperature as a Power Source,” which claimspriority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. The application is also a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/650,811, filed Feb. 11, 2022,titled “Systems for Generating Geothermal Power in an Organic RankineCycle Operation During Hydrocarbon Production Based on Wellhead FluidTemperature,” which is a continuation of U.S. Non-Provisionalapplication Ser. No. 17/305,298, filed Jul. 2, 2021, titled “Controllerfor Controlling Generation of Geothermal Power in an Organic RankineCycle Operation During Hydrocarbon Production,” now U.S. Pat. No.11,280,322, issued Mar. 22, 2022, which claims priority to and thebenefit of U.S. Provisional Application No. 63/200,908, filed Apr. 2,2021, titled “Systems and Methods for Generating Geothermal Power DuringHydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationfurther still is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/670,827, filed Feb. 14, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” which is a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/305,296, filed Jul. 2, 2021,titled “Controller for Controlling Generation of Geothermal Power in anOrganic Rankine Cycle Operation During Hydrocarbon Production,” now U.S.Pat. No. 11,255,315, issued Feb. 22, 2022, which claims priority to andthe benefit of U.S. Provisional Application No. 63/200,908, filed Apr.2, 2021, titled “Systems and Methods for Generating Geothermal PowerDuring Hydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationyet further is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/682,126, filed Feb. 28, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” which is a continuation of U.S. Non-Provisionalapplication Ser. No. 17/494,936, filed Oct. 6, 2021, titled “Systems andMethods for Generation of Electrical Power in an Organic Rankine CycleOperation,” now U.S. Pat. No. 11,293,414, issued Apr. 5, 2022, which isa continuation-in-part of U.S. Non-Provisional application Ser. No.17/305,296, filed Jul. 2, 2021, titled “Controller for ControllingGeneration of Geothermal Power in an Organic Rankine Cycle OperationDuring Hydrocarbon Production,” now U.S. Pat. No. 11,255,315, issuedFeb. 22, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties.

FIELD OF DISCLOSURE

Embodiments of this disclosure relate to generating electrical powerfrom heat generated on, in, at, about, or adjacent a drilling rig, andmore particularly, to systems and methods for generating electricalpower in an organic Rankine cycle (ORC) operation in the vicinity of adrilling rig during drilling operations to thereby supply electricalpower to one or more of operational equipment, a grid power structure,and an energy storage device.

BACKGROUND

In some instances, an organic Rankine cycle (ORC) generator or unit mayinclude a working fluid loop that flows to a heat source, such that theheat from the heat source causes the working fluid in the loop to changephases from a liquid to a vapor. The vaporous working fluid may thenflow to a gas expander, causing the gas expander to rotate. The rotationof the gas expander may cause a generator to generate electrical power.The vaporous working fluid may then flow to a condenser or heat sink.The condenser or heat sink may cool the working fluid, causing theworking fluid to change phase from the vapor to the liquid. The workingfluid may circulate through the loop in such a continuous manner, thusthe ORC generator or unit may generate electrical power.

SUMMARY

As noted, for example, organic Rankine cycle (ORC) generators or unitsmay generate electrical power via an ORC operation based on heattransfer to a working fluid. While various types of sources of heat maybe utilized, there is currently no system, method, or controlleravailable to utilize heat generated in the vicinity (e.g., at, on, in,about, or adjacent) of a drilling rig and, more particularly, to utilizeheated drilling mud and/or to optimize or ensure that drilling fluid ordrilling mud is cooled to a preselected or specified level, that theoverall energy efficiency of equipment at the drilling rig is increased,that the amount of electrical power utilized at the drilling rig isdecreased, and/or that engine performance or efficiency is increased.For example, when drilling fluid or drilling mud is utilized as thesource of heat in such operations, then a mud chiller may not beutilized or may consume less electrical power to cool the drilling fluidor drilling mud to a particular, preselected, and/or specifiedtemperature. Further, the mud chiller may utilize electrical powergenerated by the ORC unit. In other embodiments, working fluid flowingto a heat exchanger corresponding to the drilling fluid or drilling mudmay be increased or decreased to adjust generation of electrical powerand/or control temperature of the drilling fluid or drilling mud. Inother embodiments, engine performance and/or efficiency and/orelectrical power generation may be adjusted based on the amount ofworking fluid flowing to heat exchangers corresponding to heatassociated with engine exhaust and/or with fluid from an engine's waterjacket.

Accordingly, Applicants have recognized a need for systems and methodsto generate electrical power by use of heat generated in the vicinity ofa drilling rig during drilling operations to thereby supply electricalpower to one or more of in-field operational equipment, a grid powerstructure, and an energy storage device, and/or, more particularly toprovide electrical power to a mud chiller and/or increase efficiency ofa generator and/or engine at the drilling rig. The present disclosureincludes embodiments of such systems and methods.

As noted, the present disclosure is generally directed to systems andmethods for generating electrical power by use of heat generated at adrilling rig during a drilling operation. During drilling operations,drilling fluid or drilling mud is pumped through a drill string or drillpipe to and through a drill bit positioned or connected to the distalend of the drill string or drill pipe. The drill bit may break apartrock and/or other formations in the subsurface via rotation of the drillstring or drill pipe and/or via the flow of drilling fluid through thedrill bit (e.g., the flow of drilling fluid to cause the drill bit torotate) thereby forming a borehole. The drilling fluid may also cool thedrill bit. As the drill bit operates, the friction between the drill bitand the rock and/or other formations in the subsurface may generateheat. Such heat may cause the drill bit to exhibit premature wear and/orto not operate properly. Further, the heat may decrease the overalllifetime (e.g., the time that the drill bit is utilized) of the drillbit and/or other bottom-hole assembly components (e.g., drill collars,stabilizers, reamers, shocks, hole-openers, bit subs, etc.). To ensurethat the drill bit operates properly and/or to extend the life or use ofthe drill bit, the drilling fluid may be utilized to cool the drill bit.The drilling fluid may also be utilized to carry cuttings and otherdebris caused by forming the borehole. The drilling fluid may flow upthe borehole above the surface and out of the borehole via a drillingfluid return pipeline. The drilling fluid return pipeline may connectdirectly to a drilling fluid heat exchanger or may connect to thedrilling fluid heat exchanger via a control valve. The control valve maydivert a portion or all of the drilling fluid to the drilling fluid heatexchanger.

The drilling rig may include other sources of heat. For example, anengine to drive the drilling fluid pump or mud pump may produce heatedfluid via an engine's water jacket and/or heated exhaust. In suchexamples, the exhaust may be transported, via an exhaust pipeline to anexhaust heat exchanger. An exhaust control valve may be positioned alongthe exhaust pipeline to divert a portion or all of the exhaust from theexhaust heat exchanger to the atmosphere when the exhaust is outside aspecified operating range.

Another source of heat may include fluid from an engine's water (orother fluid, e.g., coolant) jacket, for example. As an engine operates,the engine may generate heat. The heat may cause parts and consumables(e.g., oil and/or seals and/or sealants) to wear out or break downfaster and/or cause formation of deposits thereby impeding airflowthrough the engine and decreasing engine performance. As such, an enginemay include a water jacket. Water or other coolant may flow through thejacket, absorb heat from the engine, and flow to a heat sink where theabsorbed heat may dissipate. In such examples, fluid from the engine'swater jacket may flow through a water jacket pipeline to a water jacketheat exchanger. A water jacket fluid control valve may be positionedalong the water jacket fluid pipeline to divert a portion or all of thewater or other coolant in the water jacket to a water jacket heatexchanger when the fluid from the engine's water jacket is within aspecified operating range.

In such embodiments, a system may include each of these heat exchangers.Each of the heat exchangers may connect to a supply manifold and areturn manifold. The amount of working fluid flowing to/from the supplymanifold and return manifold, respectively, and/or the amount of workingfluid flowing to each heat exchanger from the return manifold may becontrolled by one or more flow control devices. Adjusting the flow ofworking fluid to any of the heat exchangers may be performed based on anumber of factors, such as engine performance and/or efficiency and/orelectrical power generation may be adjusted based on the amount ofworking fluid flowing to heat exchangers corresponding to heatassociated with engine exhaust and/or with fluid from an engine's waterjacket.

Accordingly, an embodiment of the disclosure is directed to a method forgenerating power in an organic Rankine cycle (ORC) operation in thevicinity of a drilling rig. The method may include, during a drillingoperation, pumping, via a pump, drilling fluid from a drilling fluidcontainer to a proximal end of a drill pipe. The pump may be driven byan engine during the drilling operation. Further, the drilling rig mayinclude one or more additional engines to provide electrical power todrilling rig equipment. The drilling fluid may flow through an interiorof the drill pipe to the distal end of the drill pipe. The distal end ofthe drill pipe may be connected to a drill bit. The flow of drillingfluid may cause the drill bit to rotate. The rotation of the drill bitmay form a borehole in a subsurface and thereby generate a heateddrilling fluid. The heated drilling fluid may flow up the borehole to adrilling fluid return pipe above the subsurface via an annulus definedby a space between an outer surface of the drill pipe and an innersurface of the borehole. The method may include diverting, via a heatexchanger supply valve, the heated drilling fluid from the drillingfluid return pipe to a heat exchanger. The heat exchanger may bepositioned to transfer heat from the heated drilling fluid to a flow ofa working fluid to generate a cooled drilling fluid and a heated workingfluid. The heated working fluid may cause an ORC unit to generateelectrical power. The method may include returning the cooled drillingfluid to the drilling fluid container.

An embodiment of a method also may include, prior to returning thecooled drilling fluid to the drilling fluid container, degassing thecooled drilling fluid and removing cuttings included in the cooleddrilling fluid from formation of the borehole. The method further mayinclude, prior to diversion of the heated drilling fluid, sensing, via atemperature sensor positioned along the drilling fluid return pipe, atemperature of the heated drilling fluid. The method additionally mayinclude, in response to the temperature of the heated drilling fluidbeing lower than an ORC operating range, adjusting the heat exchangersupply valve to a closed position to thereby prevent heated drillingfluid to flow therethrough, and in response to the temperature of theheated drilling fluid being within an ORC operating range, adjusting theheat exchanger supply valve to an opened position to thereby divert theheated drilling fluid to the heat exchanger. The transfer of heat fromthe heated drilling fluid to the flow of the working fluid may extend atime that bottom-hole assembly components are utilized and reduces atotal amount of electrical power generated by generator sets of thedrilling rig.

In another embodiment, a method may include, during operation of (1) thepump via the engine and (2) the one or more additional engines,transporting exhaust produced by one of the engine or one or moreadditional engines to a second heat exchanger. The second heat exchangermay indirectly transfer heat from the exhaust to a flow of a secondworking fluid thereby to cause the ORC unit to generate electricalpower. The method may include, prior to transport of the exhaust to thesecond heat exchanger: sensing, via an exhaust inlet sensor, an exhaustthermal mass of the exhaust produced by one of the one or more engines;and, in response to the exhaust thermal mass being outside of an exhaustthermal mass range, adjusting an exhaust control valve to partially orfully prevent or allow flow of the exhaust from the one of the one ormore engines to the second heat exchanger. The one or more additionalengines may drive generator sets and each of the generator sets maygenerate a total of about 2 megawatts to about 10 megawatts ofelectrical power. The exhaust from the engine and one or more of theadditional engines, for example, may be about 500° Fahrenheit (F) toabout 1200° F. at about 2000 cubic feet per minute (CFM) to about 20000CFM.

In another embodiment, a method may include, during operation of (1) thepump via the engine and (2) the one or more additional engines,transporting a flow of heated coolant from a water jacket associatedwith one of the one or more engines to a third heat exchanger, the thirdheat exchanger to indirectly transfer heat from the heated coolant to aflow of a third working fluid, thereby to cause the ORC unit to generateelectrical power. The method may include, prior to transport of theheated coolant to the second heat exchanger, sensing, via a water jacketinlet temperature sensor, a heated coolant temperature of the flow ofheated coolant from the water jacket, and in response to the heatedcoolant temperature being outside of a water jacket temperature range,adjusting a water jacket control valve to prevent or allow flow of theheated coolant from the water jacket to the second heat exchanger. Theheated coolant, for example, may be about 165° F. to about 230° F. atabout 70 gallons per minute to about 250 gallons per minute.

In another embodiment, a first heat exchanger, a second heat exchanger,and a third heat exchanger may connect to a working fluid manifold andone or more working fluid flow control devices positioned therebetween.The method may include, in response to a determination that an ambienttemperature exceeds an engine operating range, increasing, via acorresponding flow control device, an amount of working fluid flowingfrom the working fluid manifold to one or more of the second heatexchanger and the third heat exchanger, and in response to adetermination that electrical power utilization of a drilling fluidchiller exceeds an operating range, increasing, via a corresponding flowcontrol device, an amount of working fluid flowing from the workingfluid manifold to the heat exchanger.

Another embodiment of the disclosure is directed to a method forgenerating power based on heat generated in the vicinity of a drillingrig. The drilling rig may be one of an on-shore drilling rig oroff-shore drilling rig. Such a method may be executed, performed, oroperate during a drilling operation. The method may include receiving,via a return pipe positioned above a subsurface, a heated drilling fluidfrom a fluid channel defined by a space between an outer surface of adrilling pipe and an inner surface of a borehole, and directing theheated drilling fluid from the drilling fluid return pipe to a heatexchanger. The heat exchanger may be positioned to transfer heat fromthe heated drilling fluid to a flow of a working fluid to generate acooled drilling fluid, thereby to cause an ORC unit to generateelectrical power. The electrical power generated may be one of directcurrent (DC) or alternating current (AC) power. On-site equipment at thedrilling rig may utilize the electrical power. Such utilization of theelectrical power by the on-site equipment may reduce total fuel usage ofthe drilling rig during the drilling operation. Electrical power may besupplied to one or more of on-site drilling rig equipment (including,but not limited to, a fluid or mud chiller), to the grid, or an energystorage device. The electrical power may be supplied to on-site drillingrig equipment during peak drilling operation hours. In otherembodiments, electrical power may be supplied to one or more of thegrid, an energy storage device, cryptocurrency miners, or drilling fluidchillers during off-peak drilling operation hours. Finally, the methodmay include returning the cooled drilling fluid to a drilling fluidcontainer.

Another embodiment of the disclosure is directed to a method forgenerating power in an organic Rankine cycle (ORC) operation in thevicinity of a drilling rig. Such a method may be executed, performed, oroperate during a drilling operation. The method may include pumping, viaa pump, drilling fluid from a drilling fluid container to a proximal endof a drill pipe. The drilling fluid may flow through an interior of thedrill pipe to the distal end. The distal end of the drill pipe may beconnected to a drill bit. The flow of drilling fluid may cause the drillbit to rotate. The rotation of the drill bit may form a borehole in asubsurface and thereby generate a heated drilling fluid. The heateddrilling fluid may flow up the borehole to a drilling fluid return pipeabove the subsurface via an annulus defined by a space between an outersurface of the drill pipe and an inner surface of the borehole. Themethod may include receiving, via a return pipe positioned above thesubsurface, the heated drilling fluid, and sensing, via a return pipetemperature sensor, a temperature of the heated drilling fluid in thereturn pipe. The method also may include sensing, via a working fluidtemperature sensor, a temperature of a flow of working fluid from a heatexchanger. The flow of working fluid may flow through the heat exchangerto facilitate transfer of heat from heated drilling fluid to the flow ofworking fluid thereby causing an ORC unit to generate electrical powerand generate cooled drilling fluid. The heat exchanger may be connectedto the return pipe via a heat exchanger valve and the heated drillingfluid may flow therethrough. The method further may include, in responseto one or more of a (1) determination that the temperature of heateddrilling fluid in the return pipe is greater than or equal to athreshold or (2) a determination that the temperature of the flow ofworking fluid from the heat exchanger is within an operating range,adjusting an opened/closed position of a heat exchanger valve to allowcontinuous diversion of the heated drilling fluid to a heat exchanger tofacilitate transfer of heat from heated drilling fluid to a flow ofworking fluid and generate cooled drilling fluid. Such determinationsmay occur at pre-determined or pre-selected intervals. The method mayinclude returning the cooled drilling fluid to the drilling fluidcontainer.

Another embodiment of the disclosure is directed to a system forgenerating power in an organic Rankine cycle (ORC) operation in thevicinity of a drilling rig during drilling operations. The system mayinclude a drilling fluid container to store an amount of drilling fluid.The system may include a container pipe including a first end and asecond end. The first end of the container pipe may be in fluidcommunication with the drilling fluid container. The system may includea drilling fluid pump in fluid communication with the second end of thecontainer pipe. The system may include a drilling fluid pipe including afirst end and a second end, the first end of the drilling fluid pipe maybe connected to the drilling fluid pump. The drilling fluid pump maypump drilling fluid therethrough. The system may include a drill stringincluding a proximal end, a distal end, an outer surface, and an innersurface. The proximal end of the drill string may be connected to thesecond end of the drilling fluid pipe. The drill string inner surfacemay define a cavity, the drilling fluid to flow therethrough. The systemmay include a drill bit connected to the distal end of the drill string.The drill bit may rotate based on rotation of the drill string and/orthe flow of the drilling fluid. The drill bit may form a borehole in asubsurface geological formation. The system may include a drilling fluidreturn pipe positioned above the subsurface geological formation andconnected to an annulus defined by an inner surface of the borehole andthe outer surface of the drill string. The drilling fluid may includeaggregate from the drill bit. The system may include a heat exchangerconnected to drilling fluid return pipe. The heat exchanger mayfacilitate heat transfer from the drilling fluid to the to transfer heatto a working fluid flow. The system may include an ORC unit to generateelectrical power using heat from the working fluid flow. The ORC unitmay include a generator, a gas expander, a condenser, an internal heatexchanger, and a loop for the flow of organic working fluid, the loopdefined by a fluid path through the condenser, generator, and a firstfluid path of the internal heat exchanger, the internal heat exchangerincluding a second fluidic path to connect to the heat exchanger and theworking fluid flowing therethrough, the internal heat exchanger toindirectly transfer heat from the working fluid to the organic workingfluid thereby causing the organic working fluid to change phases from aliquid to a vapor, the flow of the vapor to cause the generator togenerate electrical power via rotation of a gas expander as defined byan ORC operation, the condenser to cool the flow of the organic workingfluid, and the cooling to cause the organic working fluid to changephases from the vapor to the liquid.

In other embodiments, a system may include a pump engine to drive thedrilling pump, one or more generation sets to generate electrical powerfor use at the drilling rig, and one or more engines connected to and todrive the one or more generation sets. The pump engine and one or moreengines may produce exhaust. Each of the pump engine and one or moreengines may include exhaust outlets. In such embodiments, the systemalso may include one or more exhaust conduits including a first end anda second end. Each of the one or more exhaust conduit's first end may bein fluid communication with each of the exhaust outlets of the pumpengine and one or more engines. The system may include an exhaustmanifold to connect to each of the one or more exhaust conduit's secondend, the exhaust from each of the pump engine and one or more enginesmay aggregate therein, one or more exhaust heat exchangers to connect tothe exhaust manifold, to receive the aggregated exhaust from each of thepump engine and one or more engines, and configured to facilitate heattransfer from exhaust to a second working fluid.

In other embodiments, a system may include one or more water or otherfluid (e.g., coolant) jackets as will be understood by those skilled inthe art. Each of the one or more water jackets may corresponding to oneof the pump engine and one or more engines and to cool the one of thepump engine and one or more engines during drilling operation. Thesystem may include one or more water jacket heat exchangers each influid communication with one of the one or more water jackets andconfigured to facilitate heat transfer from fluid within the waterjacket to a second working fluid.

Another embodiment of the disclosure is directed to a system forgenerating power in an organic Rankine cycle (ORC) operation in thevicinity of a drilling rig during drilling operations. The system mayinclude a drilling fluid container to store an amount of drilling fluid.The system may include a container pipe including a first end and asecond end. The first end of the container pipe may be in fluidcommunication with the drilling fluid container. The system also mayinclude a drilling fluid pump in fluid communication with the second endof the container pipe. The system further may include a drilling fluidpipe including a first end and a second end. The first end of thedrilling fluid pipe may be connected to the drilling fluid pump, thedrilling fluid pump to pump drilling fluid therethrough, and a drillstring including a proximal end, a distal end, an outer surface, and aninner surface. The proximal end of the drill string may be connected tothe second end of the drilling fluid pipe. The drill string innersurface may define a cavity, the drilling fluid to flow therethrough.The system still further may include a drill bit connected to the distalend of the drill string. The drill bit may rotate based on rotation ofthe drill string and flow of the drilling fluid. The drill bit may forma borehole in a subsurface geological formation. The system also mayinclude drilling fluid return pipe positioned above the subsurfacegeological formation and connected to an annulus defined by an innersurface of the borehole and the outer surface of the drill string, thedrilling fluid, including aggregate from the drill bit, to flowtherethrough. The system still further may include a heat exchangerconnected to drilling fluid return pipe. The heat exchanger mayfacilitate heat transfer from the drilling fluid to the to transfer heatto a working fluid flow. The system also may include an ORC unit togenerate electrical power using the heat transferred to the workingfluid flow.

Another embodiment of the disclosure is directed to a controller tocontrol electrical power generated in an organic Rankine cycle (ORC)operation in the vicinity of a drilling rig during drilling operations.The controller may include an input in signal communication with adrilling fluid return pipe sensor to provide a temperature of a drillingfluid entering a drilling fluid return pipe. The controller may furtherinclude a set of inputs/outputs in signal communication with a heatexchanger valve and a working fluid flow control device. The controllermay be configured to, in response to the drilling fluid being within anoperating range, transmit one or more signals to (1) to adjust a heatexchanger valve's position to thereby divert drilling fluid to a heatexchanger or (2) to adjust the working fluid flow control device tothereby control an amount of heat transferred to the working fluid flow.The heat exchanger may facilitate transfer of heat from the drillingfluid to a working fluid flow and the heat transferred to the workingfluid may cause an ORC unit to generate electricity. The controller mayfurther include a second input in signal communication with a heatexchanger working fluid outlet temperature sensor. The heat exchangerworking fluid outlet temperature sensor may provide a working fluidoutlet temperature of a working fluid flow from the heat exchanger.Adjustment of the one or more of (1) heat exchanger valve's position or(2) working fluid flow control device may further be based on theworking fluid outlet temperature.

Another embodiment of the disclosure is directed to a method toincrease, for one or more of an engine, a generator set, or abottom-hole assembly, performance and lifespan. Such a method may beexecuted, performed, or operate during a drilling operation. The methodmay include sensing, via a drilling fluid return pipe sensor, atemperature of a flow of drilling fluid from a borehole, and sensing,via an ambient temperature sensor, an ambient temperature of a drillingrig. The method also may include determining electrical power utilizedby drilling rig equipment and generated by a generator set driven by anengine, and in response to one or more of (a) the temperature of theflow of drilling fluid from the borehole exceeding an operating range,(b) the ambient temperature exceeding an ambient temperature threshold,or (c) the electrical power utilized by the drilling rig equipmentexceeding a power requirement threshold: adjusting one or more of (1) afirst working fluid flow control device; (2) a second working fluid flowcontrol device; or (3) a third working flow control device. The firstworking fluid flow control device may control a flow of working fluid toa drilling fluid heat exchanger.

An embodiment of a drilling fluid heat exchanger, for example, may beconfigured to transfer heat from the drilling fluid to the flow of theworking fluid, the transferred heat to cause an ORC unit to generateelectrical power. Adjustment of the first working fluid flow controldevice may cause an increase in working fluid flow to the drilling fluidheat exchanger thereby causing a decrease in the temperature in drillingfluid to thereby decrease cooling via a mud chiller and to furtherthereby decrease overall electrical power utilized at the drilling rig.The second working fluid flow control device may control a flow ofworking fluid to an exhaust heat exchanger. The exhaust fluid heatexchanger may be configured to transfer heat from exhaust generated bythe engine to the flow of the working fluid, the transferred heat tocause an ORC unit to generate electrical power. Adjustment of the secondworking fluid flow control device may cause an increase in working fluidflow to the exhaust heat exchanger thereby causing an increase inoverall electrical power generated by the ORC unit due to the high heatof the exhaust and to thereby optimize engine and generator setperformance. The third working fluid flow control device may control aflow of working fluid to a water jacket heat exchanger. The water jacketfluid heat exchanger may be configured to transfer heat from waterjacket fluid of a water jacket, the water jacket configured to cool theengine, to the flow of the working fluid, the transferred heat to causean ORC unit to generate electrical power. Adjustment of the thirdworking fluid flow control device may cause an increase in working fluidflow to the water jacket heat exchanger thereby causing an increase inengine performance due to increased heat transfer from the engine to theworking fluid.

Another embodiment of the disclosure is directed to a method forgenerating power in an organic Rankine cycle (ORC) operation in thevicinity of a drilling rig. The method may include operating a drillingrig to form a borehole in a subsurface formation. The method may alsoinclude, during operation of the drilling rig, selecting one or morefluids from one or more corresponding heat sources. The one or morefluids selected may flow to one or more corresponding heat exchangers.Each of the one or more corresponding heat exchangers may be positionedto transfer heat from the heated drilling fluid to a flow of a workingfluid to generate a heated working fluid. The heated working fluid maycause an ORC unit to generate electrical power. The one or more heatsources may include exhaust produced by one of one or more enginespositioned in the vicinity of the drilling rig or fluid from a fluidjacket corresponding to one of the one or more engines. Additionally,the one or more heat sources may include drilling fluid utilized duringoperation of the drilling rig. One or more of the one or more heatsources may be selected based on temperature of fluid from each of theone or more heat sources, the ambient temperature at the drilling rig,engine optimization, electrical power output maximization, or electricalpower utilization at the drilling rig.

Another embodiment of the disclosure is directed to a method forgenerating power in an organic Rankine cycle (ORC) operation in thevicinity of a drilling rig. The method may include, during a drillingoperation, selecting, based on one or more of (a) engine optimization,(b) electrical power output maximization, or (c) electrical powerutilization at the drilling rig, diversion of an amount of one or moreof (1) engine exhaust, via a first heat exchanger supply valve, from anengine exhaust conduit to a first heat exchanger and (2) fluid, via asecond heat exchanger supply valve, from an engine fluid jacket to asecond heat exchanger. Each of the first heat exchanger and the secondheat the heat exchanger may be positioned to transfer heat from theengine exhaust and fluid to a flow of a working fluid to generate aheated working fluid. The heated working fluid may cause an ORC unit togenerate electrical power. Selection of diversion of the amount of oneor more of engine exhaust and fluid may be further based on ambienttemperature at the drilling rig, temperature of the engine exhaust,temperature of the fluid, temperature of working fluid corresponding tothe engine exhaust, and temperature of working fluid corresponding tothe fluid.

Another embodiment of the disclosure is directed to a method forincreasing one or more of engine, generator set, or bottom-hole assemblyperformance and lifespan. The method may be executed during a drillingoperation. The method may include sensing, via an ambient temperaturesensor, an ambient temperature of a drilling rig. The method may includedetermining electrical power utilized by drilling rig equipment andgenerated by a generator set driven by an engine. The method mayinclude, in response to one or more of (a) the ambient temperatureexceeding an ambient temperature threshold or (b) the electrical powerutilized by the drilling rig equipment exceeding a power requirementthreshold: adjusting one or more of (1) a first working fluid flowcontrol device, or (2) a second working fluid flow control device. Thefirst working fluid flow control device may control a flow of workingfluid to an exhaust heat exchanger. The exhaust fluid heat exchanger maybe configured to transfer heat from exhaust generated by the engine tothe flow of the working fluid. The transferred heat may cause a powergeneration unit to generate electrical power, the second working fluidflow control device may control a flow of working fluid to a fluidjacket heat exchanger. The fluid jacket fluid heat exchanger may beconfigured to transfer heat from the fluid of the fluid jacket to theflow of the working fluid. The fluid jacket may be configured to coolthe engine. The transferred heat may cause a power generation unit togenerate electrical power.

Still other aspects and advantages of these embodiments and otherembodiments, are discussed in detail herein. Moreover, it is to beunderstood that both the foregoing information and the followingdetailed description provide merely illustrative examples of variousaspects and embodiments, and are intended to provide an overview orframework for understanding the nature and character of the claimedaspects and embodiments. Accordingly, these and other objects, alongwith advantages and features of the present invention herein disclosed,will become apparent through reference to the following description andthe accompanying drawings. Furthermore, it is to be understood that thefeatures of the various embodiments described herein are not mutuallyexclusive and may exist in various combinations and permutations.

BRIEF DESCRIPTION OF DRAWINGS

These and other features, aspects, and advantages of the disclosure willbecome better understood with regard to the following descriptions,claims, and accompanying drawings. It is to be noted, however, that thedrawings illustrate only several embodiments of the disclosure and,therefore, are not to be considered limiting of the scope of thedisclosure.

FIG. 1A, FIG. 1B, and FIG. 1C are side-view perspectives ofimplementations of systems to generate electrical power at a drillingrig, according to one or more embodiments of the disclosure.

FIG. 2A, FIG. 2B, FIG. 2C, FIG. 2D, FIG. 2E, FIG. 2F, FIG. 2G, and FIG.2H are block diagrams illustrating implementations of systems of anelectrical power generation enabled drilling rig to provide electricalpower to one or more of in-field equipment, equipment at other sites,energy storage devices, and the grid power structure, according to oneor more embodiment of the disclosure.

FIG. 3 is a simplified diagram illustrating a control system formanaging electrical power production at a drilling rig, according to oneor more embodiments of the disclosure.

FIG. 4A, FIG. 4B, and FIG. 4C are flow diagrams of methods of electricalpower generation in which, during a drilling operation, working fluid isheated via one or more of drilling fluid or drilling mud, engineexhaust, and/or water (or other fluid) jacket fluid flow, according toone or more embodiments of the disclosure.

FIG. 5 is a flow diagram of a method of electrical power generation inwhich, during a drilling operation, working fluid is heated via one ormore heat sources, according to one or more embodiments of thedisclosure.

FIG. 6 is a flow diagram of a method of electrical power generation inwhich, during a drilling operation, working fluid is heated via one ormore of drilling fluid or drilling mud, engine exhaust, and/or water (orother fluid) jacket fluid flow, according to one or more embodiments ofthe disclosure.

DETAILED DESCRIPTION

So that the manner in which the features and advantages of theembodiments of the systems and methods disclosed herein, as well asothers that will become apparent, may be understood in more detail, amore particular description of embodiments of systems and methodsbriefly summarized above may be had by reference to the followingdetailed description of embodiments thereof, in which one or more arefurther illustrated in the appended drawings, which form a part of thisspecification. It is to be noted, however, that the drawings illustrateonly various embodiments of the systems and methods disclosed herein andare therefore not to be considered limiting of the scope of the systemsand methods disclosed herein as it may include other effectiveembodiments as well.

The present disclosure is directed to embodiments of systems and methodsfor generating electrical power (e.g., via a power generation unit suchas an organic Rankine cycle (ORC) operation or other operationsutilizing heat to generate electrical power as will be understood bythose skilled in the art) based on heat from a flow of drilling fluid ormud and other sources (e.g., engine exhaust, coolant from an engine'swater jacket, other heat generating equipment or devices, etc.) tothereby supply electrical power to one or more of equipment oroperational equipment, a grid power structure, an energy storage device,and/or other devices. Drilling rig operations typically include pumpingof drilling fluid or drilling mud through a drill string or drill pipeto a drill bit connected to the drill string or drill pipe at the drillstring or drill pipe's proximal end. The drilling fluid may cool thedrill bit and, in some embodiments, other bottom-hole assemblycomponents or devices. During the drilling operation, the drill bit'stemperature may increase due to the friction between the drill bit andthe rock and/or other substrate of the subsurface formation. After thedrilling fluid cools the drill bit, the drilling fluid may flow or maybe pumped or transmitted to the surface (e.g., to a drilling fluidreturn pipeline) via an annulus defined by a space between the outersurface of the drill string or drill pipe and the surface or innersurface of the borehole. The drilling fluid may flow, via the drillingfluid return pipeline, to a drilling fluid tank, container, or pit.Other equipment or devices may be positioned therebetween. For example,a fluid or mud chiller and/or shale shaker may be positioned prior tothe drilling fluid tank, container, or pit. The heat generated orcarried by the drilling fluid or drilling mud, as well as the heatproduced by the equipment on-site (e.g., engine exhaust and/or coolingfluid in a water jacket of an engine, computing devices or systems,and/or any other equipment which generates heat during drillingoperations), may be utilized via either external and/or internal heatexchangers to produce electrical power (e.g., via one or more ORC unitsor other equipment configured to convert heat to electrical power).

In such examples, ORC generators or units, for example, may use apipeline in communication with heat sources to allow a working fluid tochange phase from liquid to vapor. As the working fluid changes phasefrom a liquid to a vaporous state, the vaporous state working fluid mayflow up the pipe or pipeline to a gas expander. The vaporous stateworking fluid may flow through and cause the gas expander to rotate. Therotation of the gas expander may cause a generator to generateelectrical power, as will be described below. The vaporous state workingfluid may flow through the gas expander to a heat sink, condenser, orother cooling apparatus. The heat sink, condenser, or other coolingapparatus may cool the working fluid thereby causing the working fluidto change phases from a vapor to a liquid.

In the present disclosure, a drilling fluid return pipeline may connectdirectly to an inlet of a drilling fluid heat exchanger or may connectto a secondary supply pipeline via a drilling fluid control valve, thesecondary supply pipeline connecting to the inlet of the drilling fluidheat exchanger. In such embodiments, the drilling fluid may flowdirectly to and through the drilling fluid heat exchanger or thedrilling fluid control valve may divert a portion or all of the drillingfluid to the drilling fluid heat exchanger. The drilling fluid may flowthrough the drilling fluid heat exchanger thereby facilitating transferof heat from the flow of drilling fluid to a working fluid.

Sensors to sense or determine various characteristics of the drillingfluid and/or other heated fluid from other equipment may be positionedthroughout the drilling rig. In such an embodiment, the drilling fluidcontrol valve's position may be adjusted to increase or decrease theamount of drilling fluid flowing to the drilling fluid heat exchanger.Similar valves may be included for each heat source. Further, each heatexchanger may connect to a return manifold and a supply manifold, eachmanifold positioned between the heat exchangers and the ORC unit. Thesupply manifold and/or the return manifold may include flow controldevices to adjust the amount of working fluid flowing to any particularheat exchanger, thus enabling control of electrical power output and/orother factors.

For example, adjustment of a first working fluid flow control device maycause an increase or decrease in a working fluid flow to the drillingfluid heat exchanger thereby causing a decrease or increase,respectively, in the temperature in drilling fluid. Based on theincrease or decrease of working fluid to the drilling fluid heatexchanger and a preselected or predetermined temperature of the drillingfluid, a mud chiller may or may not be utilized to a degree to cool thedrilling fluid further. The mud chiller may utilize electrical power. Asthe temperature of the drilling fluid increases, the electrical powerutilized by the mud chiller may increase. In an embodiment, to offsetsuch an increase in utilized electrical power, the ORC unit may supplyelectrical power to the mud chiller.

As noted, other heat sources may be utilized, for example engine exhaustand/or fluid from an engine's water (or other coolant) jacket. In suchembodiments, a second working fluid flow control device may control aflow of working fluid to an exhaust heat exchanger. The exhaust fluidheat exchanger may be configured to transfer heat from exhaust generatedby the engine to the flow of the working fluid, the transferred heat tocause an ORC unit to generate electrical power. Adjustment of the secondworking fluid flow control device may cause an increase or decrease inworking fluid flow to the exhaust heat exchanger. An increase in workingfluid may cause an increase in overall electrical power generated by theORC unit due to the high heat of the exhaust. Such an action may beperformed to optimize engine and generator set performance (e.g., theengine may be utilized to generate a lesser amount of electrical power).A third working fluid flow control device may control a flow of workingfluid to a water jacket heat exchanger (or a heater exchanger that usesanother type of coolant, for example). The water jacket fluid heatexchanger may be configured to transfer heat from water jacket fluid ofa water jacket, the water jacket configured to cool the engine, to theflow of the working fluid, the transferred heat to cause an ORC unit togenerate electrical power. Adjustment of the third working fluid flowcontrol device may cause an increase or decrease in working fluid flowto the water jacket heat exchanger. Increasing flow of working fluid tothe water jacket heat exchanger may cause an increase in engineperformance due to increased heat transfer from the engine to theworking fluid (e.g., extending life of consumables and parts of theengine, as well as increasing engine efficiency and/or output).

After passing through the heat exchanger, the drilling fluid may becooled for a period of time in the drilling fluid tank or container.After a period of time or preselected or predetermine time interval inthe drilling fluid tank the drilling fluid may be cooled radiantly. Inother words, as the drilling fluid resides in the tank, over time, thedrilling fluid may cool or the drilling fluid temperature may decrease.In such embodiments, as the drilling fluid is pumped from the drillingfluid tank, the drilling fluid may be pumped through a drilling fluidchiller, also known as a mud chiller. The mud chiller, utilizingelectrical power, may further cool the drilling fluid. The drillingfluid pumped from the drilling fluid tank may be pumped back through thesame fluidic path again (e.g., back to the drill string or drill pipe)and the operation repeated for the duration of the drilling operation.Thus, heat from the flow of drilling fluid, exhaust, fluid from a waterjacket (or other coolant jacket), and/or other fluid may be utilized togenerate electrical power in a power generation unit such as an ORC unitas will be understood by those skilled in the art, while increasingefficiency of and/or optimizing drilling rig operations.

Such embodiments of systems, for example, may include variouscomponents, devices, or apparatuses, such as temperature sensors,pressure sensors or transducers, flow meters, control valves, smartvalves, valves actuated via control signal, controllers, a master orsupervisory controller, other computing devices, computing systems, userinterfaces, in-field equipment, and/or other equipment as will beunderstood by those skilled in the art. The controller, for example, maymonitor and adjust various aspects of the system to ensure that a flowof gas does not drop below the threshold where volatiles may condense inthe flow of gas, that the temperature of the flow of gas stays below thethreshold where a compressor or pump provides a higher output, that theflow of gas remains within a selected operating range, that the workingfluid remains within a selected operating range, and/or that electricalpower is generated efficiently and economically.

FIG. 1A, FIG. 1B, and FIG. 1C are side-view perspectives of exampleimplementations of systems to generate electrical power at a drillingrig, according to one or more embodiments of the disclosure. A drillingrig 100, as illustrated in FIG. 1A, may include various equipment and/ordevices. The equipment and/or devices may include a drilling fluid tank,also referred to as a drilling fluid pit or drilling fluid container.The drilling fluid tank (e.g., a mud tank 130) may store drilling fluid(e.g., drilling mud). The drilling fluid tank may be comprised of steelor other metal configured to withstand corrosion. The drilling fluidtank may store varying amounts of drilling fluid. The amount of drillingfluid may vary at different time intervals as the length of the boreholeincreases and/or as additional drilling fluid is added to the drillingfluid tank. The drilling fluid, also referred to as drilling mud, mayinclude a water-based mud (e.g., dispersed or non-dispersed),non-aqueous mud (e.g., oil based mud), and/or a gaseous drilling fluid.During drilling operations, the drilling fluid may be pumped (e.g., viaa pump 134 driven by an engine 136) to a drill bit 118 to cool the drillbit 118, carry cuttings, and/or to provide hydrostatic pressure (e.g.,preventing formation fluids from entering the borehole 120).

The drilling rig 100, as noted, may include a pump 134 to pump thedrilling fluid to a borehole 120. The pump 134 may first pump thedrilling fluid from the drilling fluid tank via drilling fluid inputpipe 132. The pump 134 may pump such fluid through a stand pipe 104. Inother embodiments, the stand pipe 104 may be a goose neck pipe, a kellyhose, another pipeline or hose configured to withstand high pressure, orsome combination thereof. The stand pipe 104 may pass through and/or besupported by a swivel 110. The swivel 110 may connect to a travel block108 and the travel block 108 may connect to a crown block 106. The crownblock 106 may be stationary and may be configured to raise and lower thetravel block 108 thereby allowing the stand pipe 104 or other pipelineor hose to move in a vertical direction. The stand pipe 104 may passthrough a table 114 at the drill floor 112. The stand pipe 104 may thenconnect to the drill string 116 or drill pipe thereby allowing drillingfluid to be pumped through the stand pipe 104 to an inner cavity of thedrill string 116. The inner cavity of the drill string 116 may bedefined by the space substantially within the inner surface of the drillstring 116.

The drill string 116 may include a proximal end and a distal end. Theproximal end may connect to the stand pipe 104. The distal end mayinclude or may be connected to a drill bit 118. The drill string 116 mayrotate, via the rotary table 114 and/or other equipment or devices, aswill be understood by a person skilled in the art. As the drill stringrotates 116, the drill bit 118 may rotate. In another embodiment, inaddition to or rather than the rotation of the drill string 116 causingrotation of the drill bit 118, the drilling fluid pumped through thedrill string 116 may cause the drill bit 118 to rotate. As the drill bit118 rotates, the drill bit 118 may cut or break apart rock and/or othermaterials in the subsurface formation. Such an action may create aborehole 120 in the subsurface formation, which may be utilized forvarious purposes, including, but not limited to, for oil and gasextraction (e.g., via fracturing or a well), water well formation,carbon dioxide sequestration, and/or geothermal well generation.

The pump 134 may be driven by an engine 136. In an embodiment, therotary table 114 or the rotation of the drill string 116 may be drivenby the engine 136 and/or another engine. Further, additional enginesand/or generators or generator sets (e.g., to provide electrical powerto equipment and/or devices at the drilling rig 100) may be included orpositioned at the drilling rig 100. Such additional engines may beutilized to generate electrical power and/or drive other equipmentand/or devices. The engine 136 and/or other additional engines at thedrilling rig 100 may include a water (or other fluid) jacket as will beunderstood by those skilled in the art. Further, the engine, duringoperation, may produce exhaust. In other embodiments, the engine 136 maybe an electric engine and, thus, no exhaust may be produced. The pump134 may be in fluid communication with the mud tank 130, for example,via pipeline 132 (e.g., a tank or container pipe or pipeline). As thepump 134 is driven by the engine 136, the drilling fluid may flowthrough the pump 134 to the stand pipe 104 and from the stand pipe 104to the drill string 116. The drilling fluid may flow through and/oraround the drill bit 118, thus cooling the drill bit 118 and carryingcuttings up the borehole 120 (e.g., via an annulus defined by a spacebetween an outer surface of the drill string 116 and an inner surface ofthe borehole 120).

As the drilling fluid flows up the borehole 120, the drilling fluid mayreach a drilling fluid return pipeline 122. The drilling fluid returnpipeline 122 may, in an embodiment, connect directly to a heat exchanger124 (e.g., a drilling fluid heat exchanger). In another embodiment, thedrilling fluid return pipeline 122 may connect to the mud tank 130 orother equipment (e.g., a shale shaker 128 or filter, a degasser, and/ora mud chiller) positioned therebetween. For example, the drilling fluidreturn pipeline 122 may connect to a shale shaker 128. The shale shaker128 may remove any solids from the drilling fluid flowing therethrough.The shale shaker 128 may connect to the heat exchanger 124 and the heatexchanger may connect to the mud tank 130. In another embodiment, asecond pipeline may be connected to the drilling fluid return pipeline122. The second pipeline may include a control valve and the drillingfluid return pipeline 12 may include a control valve. Thus, based onvarious factors, the amount of drilling fluid flowing to the heatexchanger 124 may be controlled. In the embodiments, the heat exchanger124 may connect to the mud tank 130 via a third pipeline 126.

In an embodiment, different types of heat exchangers may be utilized atthe drilling rig 100. The heat exchanger 124 may be internal to the ORCunit 142 and/or external to the ORC unit 142. In an embodiment, the heatexchanger 124 may be a shell and tube heat exchanger, a spiral plate orcoil heat exchanger, a heliflow heat exchanger, or another heatexchanger configured to withstand high temperatures, high pressure,and/or corrosive fluids. To prevent damage or corrosion to the heatexchanger 124 over a period of time, the fluid path inside the heatexchanger 124 for the flow of drilling fluid may be configured towithstand damage or corrosion by including a permanent coating, asemi-permanent coating, a temporary anti-corrosive coating, an injectionpoint for anti-corrosive chemical additive injections, and/or somecombination thereof. Further, at least one fluid path of the heatexchanger 124 may be comprised of an anti-corrosive material, e.g.,anti-corrosive metals or polymers.

The direction of drilling fluid flowing through the heat exchanger 124may be opposite of the flow of working fluid flowing through the heatexchanger 124, thereby the heat exchanger 124 facilitates transfer ofheat from the drilling fluid to the working fluid. The working fluid mayflow from the ORC unit 142 to the heat exchanger via pipeline 140. Afterheat transfer within the heat exchanger 124, the working fluid may flowthrough pipeline 138 to the ORC unit 142, thereby causing an ORCoperation to occur and electrical power 144 to be generate. In anotherembodiment, the heat exchanger 124 may be internal to the ORC unit 142and, in such embodiments, pipeline 140 and pipeline 138 may be internalto the ORC unit 142.

In an example, the working fluid may be a fluid with a low boiling pointand/or high condensation point. In other words, a working fluid may boilat lower temperatures (for example, in relation to water), whilecondensing at higher temperatures (e.g., in relation to water) as willbe understood by a person skilled in the art. The working fluid may bean organic working fluid. The working fluid may be one or more ofpentafluoropropane, carbon dioxide, ammonia and water mixtures,tetrafluoroethane, isobutene, propane, pentane, perfluorocarbons, otherhydrocarbons, a zeotropic mixture of pentafluoropentane andcyclopentane, other zeotropic mixtures, and/or other fluids or fluidmixtures. The working fluid's boiling point and condensation point maybe different depending on the pressure within the working fluidpipelines e.g., the higher the pressure, the higher the boiling point.In another example, the working fluid may be an intermediate workingfluid. The intermediate working fluid may be a fluid with a higherboiling point. For example, the intermediate working fluid may be wateror a water glycol mixture. In such examples, as heat is transferred fromthe flow of drilling fluid, the exhaust, the fluid from the water (orother fluid) jacket, and/or from another source, the intermediateworking fluid may, rather than exhibiting a vaporous phase change,remain in a liquid phase, while retaining the transferred heat. As aliquid, the higher boiling point intermediate working fluid may be moremanageable and/or easier to transport through the pipelines. In suchexamples, the ORC unit 142 may include an internal heat exchanger.

In an embodiment, the ORC unit 142 may include a generator, a gasexpander, a condenser, an internal heat exchanger, a loop for the flowof working fluid, or some combination thereof. As an intermediateworking fluid or other fluid flows into the ORC unit 142, the internalheat exchanger may facilitate transfer of heat in the intermediateworking fluid or other fluid to a working fluid of the ORC unit 142. Theheat may cause the working fluid of the ORC unit 142 to exhibit a phasechange from a liquid to a vapor. In another embodiment, the workingfluid may enter the ORC unit 142 as a vapor or vaporous working fluid(e.g., such an ORC unit 142 may not include an internal heat exchanger).The vaporous working fluid may flow into the gas expander. In anexample, the gas expander may be a turbine expander, positivedisplacement expander, scroll expander, screw expander, twin-screwexpander, vane expander, piston expander, other volumetric expander,and/or any other expander suitable for an ORC operation or cycle. As gasflows through the gas expander, a rotor or other component connected tothe gas expander may begin to turn, spin, or rotate. The rotor mayinclude an end with windings. The end with windings may correspond to astator including windings and a magnetic field (e.g., the end withwindings and stator with windings being a generator). As the rotor spinswithin the stator, electricity may be generated. Other generators may beutilized, as will be understood by those skilled in the art. Thegenerator may produce DC power, AC power, single phase power, or threephase power. The vaporous working fluid may then flow from the gasexpander to a condenser, where the vaporous working fluid may exhibit aphase change back to the liquid working fluid. The liquid working fluidmay then flow back to the internal heat exchanger, the processrepeating.

The electrical power 144 may be transferred to or utilized by theequipment at the site 100 (e.g., a mud chiller 176 and/or otherequipment), to an energy storage device (e.g., if excess power isavailable), to equipment at other nearby sites, to the grid or gridpower structure (e.g., via a transformer through power lines), to othertypes of equipment (e.g., cryptographic currency and/or block chainminers, hydrolyzers, carbon capture machines, nearby structures such asresidential or business structures or buildings, and/or other powerdestinations), or some combination thereof. Such electrical power 100may be utilized at the drilling rig 100 in lieu or in addition tooelectrical power generate by a generator or generator set driven byadditional engines.

Turning to FIG. 1B and as noted, the engine 136 or one or more enginesmay produce exhaust exhibiting high heat or temperature. The exhaust maybe transported via an exhaust duct 146 or pipeline to a heat exchanger148 or ORC unit 142 (e.g., via pipeline 152). After the exhaust flowsthrough the heat exchanger 148 or the ORC unit 140, the exhaust may beoutput to the atmosphere, via an exhaust outlet duct 150. In anotherembodiment, prior to output of the exhaust to the atmosphere, theexhaust may pass through a filter 156 or catalyst. The filter 156 mayremove specific chemicals deemed harmful to the environment. In anotherembodiment, prior to input into the heat exchanger 148, the exhaust maybe filtered or pass through a catalyst to prevent buildup within theheat exchanger 148. If additional engines are positioned at the drillingrig 100, then, in an embodiment, the exhaust from such additionalengines may be transported to the heat exchanger 148 or ORC unit 142 ormay be transported to one or more additional heat exchangers.

In an embodiment, sensors and/or meters may be disposed throughout thedrilling rig 100. The sensors and/or meters may be temperature sensors,densitometers, density measuring sensors, pressure transducers, pressuresensors, flow meters, turbine flow meters, mass flow meters, Coriolismeters, spectrometers, other measurement sensors to determine atemperature, pressure, flow, composition, density, or other variables aswill be understood by those skilled in the art, or some combinationthereof. Further, the sensors and/or meters may be in fluidcommunication with a fluid to measure the temperature, pressure, or flowor may indirectly measure flow (e.g., an ultrasonic sensor). In otherwords, the sensors or meters may be a clamp-on device to measure flowindirectly (such as via ultrasound passed through the pipeline to thefluid).

In an embodiment, the exhaust duct 146 or pipeline may include anexhaust valve. In an embodiment, the exhaust from the engine 136 may beat a high temperature or have a high thermal mass (e.g., temperature ofthe exhaust multiplied by the flow rate of the exhaust). If thetemperature or thermal mass of the exhaust (e.g., as measured by atemperature sensor) is outside of a range (e.g., defined by theoperating temperature range of the heat exchanger 148, ORC unit 142, orother equipment or devices interacting with the exhaust and/or based onthermal mass) or above or below a threshold, the exhaust control valvemay close, thereby partially or fully preventing the exhaust fromflowing to the heat exchanger 148. If the exhaust control valve is fullyclosed, the exhaust may be fully diverted to a typical exhaust output.If the exhaust control valve is partially closed, the exhaust may bepartially diverted to a typical exhaust output, while the remainingportion may flow to the heat exchanger 148. The partial or fullprevention of the flow of exhaust to the heat exchanger 148 may preventinterruption of catalyst performance of the engine 136 and/or depositionof particulates in equipment.

In another embodiment, the flow of exhaust, prior to flowing through theheat exchanger 148, may pass through a filter, converter, or some otherdevice to reduce particulates within the exhaust. As noted, the exhaustmay cause scaling and/or deposition of such particulates. The filter orother device may ensure that the heat exchanger 148 may not exhibit suchscaling and/or deposition of particulates or may not exhibit the scalingand/or deposition at rates higher than if there were no filter or otherdevice.

The engine 136 or one or more engines may include a water (or otherfluid) jacket. As an engine 136 operates, the water or other coolant(i.e., fluid) inside the water jacket may indirectly remove heat fromthe engine 136. Heat from the engine 136 may be transferred to the wateror other coolant, thereby producing heated water or other coolant. Theheated water or other coolant may pass through a radiator, heat sink, orother type of heat exchanger to reduce the temperature of heated wateror coolant, the cooled water or coolant then flowing back to the waterjacket to cool the engine 136. In an embodiment, the output of the waterjacket may connect to a pipeline 158 to divert the flow of water to theheat exchanger 160.

In an embodiment, a water jacket control valve may be positioned on thepipeline to control the flow water or coolant from the water jacket. Apipeline 162 may be connected to the input of the water jacket to returnthe water or other coolant to the water jacket. In such embodiments,rather than or in addition to the water or other coolant passing throughthe typical radiator or heat exchanger, the heated water or othercoolant may pass through heat exchanger 160 thereby transferring heat toa working fluid. The working fluid may flow, in one embodiment, to theORC unit 142 via pipeline 164 and the working fluid may return to heatexchanger 160 via pipeline 166. In another embodiment, the engine's 136water jacket may be configured to transport the water or other coolantdirectly to the ORC unit 142. In another embodiment, the water jacketcontrol valve may close if the water or other coolant is outside aselected operating range (e.g., if the water or other coolant is toocool, then, if utilized, water or other coolant may not be sufficientfor the ORC unit 142 to generate electrical power, and/or if the wateror coolant is too hot, then, if utilized, the heated water or othercoolant may damage equipment not rated for a high temperature) thuspreventing fluid from flowing to the heat exchanger 160 and/or the ORCunit 142. Temperature of the water or coolant may be determined orsensed via one or more temperature sensors. The temperature of theworking fluid or intermediate working fluid may be determined or sensedvia one or more temperature sensors.

As noted, heat may be transferred from the engine's 136 exhaust, fromworking fluid, and/or from drilling fluid to an intermediate workingfluid or a working fluid. The intermediate working fluid may be storedin another storage tank or expansion tank. The temperature of theintermediate working fluid flowing from the heat exchanger 148 may bedetermined based on measurements from temperature sensors proximate tothe heat exchanger 148. The temperature of the intermediate workingfluid may be measured at various other points, such as after the storagetank or the storage tank control valve or prior to entry into the heatexchanger. Based on these measurements, a storage tank control valve mayopen or close to prevent or allow the storage tank to fill up and/or toprevent over-filling the storage tank. In an embodiment, the storagetank may be an expansion tank, such as a bladder or diaphragm expansiontank. The expansion tank may accept a varying volume of the intermediateworking fluid as the pressure within the working fluid pipeline varies,as will be understood by a person skilled in the art. Thus, theexpansion tank may manage any pressure changes exhibited by theintermediate working fluid.

In an embodiment, various temperature sensors and/or other sensors ormeters may be disposed and/or positioned throughout the drilling rig100. In another embodiment, the heat exchangers and/or ORC unit or unitsmay be added to the site as a kit. In such examples, temperature sensorsand/or other sensors or meters, in addition to control valves and/orother devices or equipment, may be included in the added kit (e.g.,along added or installed conduits or pipelines) installed at a drillingrig 100, rather than in existing equipment.

The drilling rig 100, as shown, utilizes an ORC unit 142 to generateelectrical power. In another embodiment, rather than or in addition tothe ORC unit 142, other geothermal-based generators may be utilized togenerate electrical power using the heat transferred to the workingfluid from the flow of drilling fluid, engine exhaust, and/or fluid froma water jacket. For example, the geothermal-based generator may beanother type of binary-cycle generator. In another embodiment, one ormore of the one or more heat sources (e.g., the heat from the drillingfluid, engine exhaust, and/or fluid from the water jacket, among otherheat sources) may be utilized to generate electrical power in the ORCunit 142 or other geothermal-based generators based on a number offactors, the factors including but not limited to, an amount ofelectrical power utilized at the drilling rig 100, engine performance,engine life expectancy, drill bit and/or bottom-hole assembly componentlife expectancy, ambient temperature, and/or other aspects.

Additionally, as illustrated in FIG. 1B and FIG. 1C, the drilling rig100 may include additional heat exchangers and a return manifold 174 andsupply manifold 172. In another embodiment, the drilling rig 100 mayinclude additional ORC units. As illustrated in FIG. 1B and FIG. 1C,each heat exchanger may connect to a supply manifold 172 to transportthe flow of working fluid to the intake of an ORC unit 142. Further,each heat exchanger may connect to a return manifold 174 to receive theworking fluid from the ORC unit 174. In another embodiment, the supplymanifold 172 and/or return manifold 174 may control, either directly orindirectly (e.g., via another flow control device), the amount or rateof flow of working fluid flowing to the ORC unit 142 and/or to each heatexchanger.

In another embodiment, the drilling rig 100 may include a separatesupply manifold and return manifold for hot working fluid supply/returnand for cool working fluid supply/return. In such examples, the separatesupply manifolds and return manifolds may control the flow of workingfluid based on temperature of the working fluid from each source (e.g.,each heat exchanger).

In FIG. 1C, the drilling rig 100 may include a mud chiller 176. Asnoted, the drilling fluid may cool the drill bit 118 to extend the lifeor use of the drill bit 118 and/or other bottom-hole assemblycomponents. As such, the drilling fluid may be cooled further prior topumping the drilling fluid back to the drill bit 118 (e.g., via the samefluidic path described herein). In some examples, the heat exchanger 124may sufficiently cool the drilling fluid. In other examples, thedrilling fluid may reside in the mud tank 130 for a period of time or apreselected or predetermined time interval sufficient to cause thedrilling fluid to radiantly cool to a specified temperature. In otherexample, a mud chiller 176 may be included to further cool the drillingfluid. The mud chiller 176 may utilize electrical power generated by agenerator or generator set. The mud chiller 176 may be positioned priorto (as illustrated in FIG. 1C) or after the pump 134. As drilling fluidis pumped from the mud tank 130, the drilling fluid may pass through themud chiller 176, the mud chiller 176 further cooling the drilling fluid.In such examples, to lower reliance on fossil fuel generated electricalpower, the mud chiller 176 may utilize electrical power generated by theORC unit 142, in addition to or rather than electrical power from agenerated by a generator or generator set.

FIG. 2A, FIG. 2B, FIG. 2C, FIG. 2D, FIG. 2E, FIG. 2F, FIG. 2G, and FIG.2H are block diagrams illustrating example implementations of anelectrical power generation enabled drilling rig to provide electricalpower to one or more of in-field equipment, equipment at other sites,energy storage devices, and the grid power structure, according to oneor more embodiment of the disclosure. Turning first to FIG. 2A, adrilling rig 200 may include one or more heat sources. The one or moreheat sources may include drilling fluid from a drilling fluid returnpipe 202, exhaust from an engine exhaust port 204, water or othercoolant from a water jacket 206, additional engines (e.g., providingadditional exhaust and/or fluid from a water jacket) among othersources.

The drilling fluid from the drilling fluid return pipe 202 may, aftercooling the drill bit of a drilling rig 200, be heated to about 100degrees Fahrenheit to about 500 degrees Fahrenheit, or in some examples,hotter than 500 degrees Fahrenheit. As the heated drilling fluid flowsinto or from the drilling fluid return pipe 202, the temperature of thedrilling fluid may be determined or sensed (e.g., via sensor 278 asillustrated in FIG. 2G). If the temperature of the drilling fluid iswithin a specified or preselected temperature range, control valve 216may open to a position to allow a portion or all of the drilling fluidto flow therethrough to the heat exchanger 218. Further, if thetemperature of the drilling fluid is above or below the specified orpreselected temperature range, then the control valve 216 may closefully or partially and the control valve 214 may open fully orpartially, thus drilling fluid is directed directly, at least partially,to a drilling fluid tank 220. If drilling fluid flows through the heatexchanger 218, then the heat exchanger 218 may facilitate heat transferfrom the drilling fluid to a working fluid. The heated working fluidproduced by heat exchanger 218 may flow to the ORC unit A 234A and maycause the ORC unit A 234A to generate electrical power 236.

The exhaust from the engine exhaust port 204 may be heated to about 500degrees Fahrenheit to about 1200 degrees Fahrenheit. The exhaust mayexit the engine at about 2000 cubic feet per minute to about 20000 cubicfeet per minute. As the exhaust flows from the engine exhaust port 204,the temperature and/or thermal mass of the exhaust may be determined orsensed (e.g., via sensor 284 as illustrated in FIG. 2G). If thetemperature of the exhaust is within a specified or preselectedtemperature or thermal mass range, control valve 222 may open to aposition to allow a portion or all of the exhaust to flow therethroughto the heat exchanger 210. Further, if the temperature of the exhaust isabove or below the specified or preselected temperature or thermal massrange, then the control valve 222 may close fully or partially and thecontrol valve 224 may open fully or partially, thus exhaust is directeddirectly, at least partially, to the atmosphere. If exhaust flowsthrough the heat exchanger 210, then the heat exchanger 210 mayfacilitate heat transfer from the exhaust to a working fluid. The heatedworking fluid may flow to the ORC unit B 234B and may cause the ORC unitB 234B to generate electrical power 236.

The fluid from the water jacket 206 may, after cooling the engine at adrilling rig 200, be heated to about 165° F. to about 230° F. at rate ofabout 70 gallons per minute to about 250 gallons per minute. As thefluid flows from the water jacket 206, the temperature of the fluid maybe determined or sensed (e.g., via sensor 292 as illustrated in FIG.2G). If the temperature of the fluid is within a specified orpreselected temperature range, control valve 228 may open to a positionto allow a portion or all of the drilling fluid to flow therethrough tothe heat exchanger 212. Further, if the temperature of the fluid isabove or below the specified or preselected temperature range, then thecontrol valve 228 may close fully or partially and the control valve 230may open fully or partially, thus the fluid is directed directly, atleast partially, to a heat sink 232. If the fluid flows through the heatexchanger 212, then the heat exchanger 212 may facilitate heat transferfrom the fluid to a working fluid. The heated working fluid may flow tothe ORC unit C 234C and may cause the ORC unit C 234C to generateelectrical power 236.

In an embodiment, one or more of the heat sources may be utilized togenerate electrical power 236 in any of the ORC units present at thedrilling rig 200. For example, drilling fluid may be utilized, inaddition to engine exhaust, to generate electrical power 236 in ORC unitA 234A and ORC unit B 234B (as illustrated in FIG. 2A), respectively. Insuch an example, heat from the engine exhaust and drilling fluid may beutilized to maximize the amount of electrical power 236 generated, asthe engine exhaust may exhibit high temperatures and a cooled drillingfluid may not be cooled further or be cooled less by a mud chillerthereby less electrical power is utilized at the drilling rig 200overall. In another example, engine exhaust and/or fluid from the water(or other fluid) jacket 206 may be utilized to generate electrical power236 in ORC unit 246 (as illustrated in FIG. 2B). In such an example,heat from the engine exhaust and/or fluid from the water jacket 206 maybe utilized to maximize electrical power 236 and engine performance, asthe engine exhaust, as noted, may exhibit a high temperature andtransferring heat from the fluid from the water jacket 206 may cool suchfluid to a temperature lower than normal thereby enabling additionalheat to be transferred from the engine to the fluid in the water jacket206 and causing the engine to operate for longer (e.g., less wear onparts and/or consumables) and operate at higher efficiency.

As illustrated in FIG. 2B, the drilling rig 200 may include a supplymanifold 242 and a return manifold 244. In such examples, the workingfluid may coalesce or combine at each manifold (e.g., the supplymanifold 242 and the return manifold 244). For example, the workingfluid may flow from each of the heat exchangers 210, 212, 218, and up to240 and combine at the supply manifold 242. The working fluid may thenflow through the ORC unit 246 then back to the return manifold 244,where the working fluid may then flow back to each of the heatexchangers 210, 212, 218, and up to 240. The supply manifold 242 and/orreturn manifold 244 may each include (e.g., internal to or external andproximate to) flow control devices configured to adjust the amount ofworking fluid flowing to each heat exchanger, thus various aspects ofthe drilling rig 200 may be controlled (e.g., electrical powergeneration, engine performance, drill bit and/or bottom-hole assemblycomponent life span, and/or other aspects). As noted and describedherein, the flow drilling fluid, exhaust, and/or fluid from a waterjacket, among other fluids from other heat sources, may flow to one ofthe one or more exchangers 210, 212, 218, and up to 240 via variousvalves and pipeline. The supply manifold 242, return manifold 244, theflow control devices, the sensors, and/or any other devices described inFIGS. 2A-2H may be positioned or disposed at various points in betweenthe ORC units and heat exchangers in FIG. 1A through FIG. 1C.

In FIG. 2C, each pipeline from the heat exchangers 210, 212, 218, and upto 240 to the supply manifold 242 may include a sensor (e.g., sensor274, 286, 294, and 299 as illustrated in FIG. 2G), such as a temperaturesensor, flow meter, or other sensor may measure or sense somecharacteristic of the working fluid. Each pipeline from the returnmanifold 244 to the heat exchangers 210, 212, 218, and up to 240 mayinclude a sensor (e.g., sensor 272, 282, 290, and 298 as illustrated inFIG. 2G), such as a temperature sensor, flow meter, or other sensor tomeasure some characteristic of the working fluid. Further, the pipelinepositioned between the return manifold 244 and the ORC unit 246 mayinclude one or more flow control devices 254, 258, in addition to one ormore sensors 252, 256 (e.g., temperature sensors or some other suitablesensor), thereby controlling the flow of working fluid from the ORC unit246 to the return manifold 244. Each pipeline from the return manifold244 to the heat exchangers 210, 212, 218, and up to 240 may furtherinclude a flow control device 248A, 248B, 248C, and up to 248N therebycontrolling the flow of the working fluid from the return manifold 244to each of the heat exchangers 210, 212, 218, and up to 240. Utilizingvarious combinations of each sensor and each flow control device, thetemperature and flow of the working fluid may be concisely controlled.The pipeline from the supply manifold 242 to the ORC unit 246 caninclude a sensor 250 to measure temperature or some other characteristicof the working fluid. Based on the measurements or determinations of thetemperature or other characteristic of the working fluid (e.g., flow,pressure, density, etc.), the flow control devices may adjust the amountof working fluid flowing to each of the one or more heat exchangersensuring that the proper amount of working fluid flows to each of theone or more exchangers. For example, one of the heat exchangers may notbe producing heat for use in the ORC unit 246. In such examples, theflow control device associated with that particular heat exchanger mayprevent further flow of working fluid to the that heat exchanger.

In FIG. 2D, the flow control devices positioned between the returnmanifold 244 and each of the one or more heat exchangers 210, 212, 218,and up to 240 may be control valves 264A, 264B, 264C, and up to 264N.The flow control devices between the return manifold 244 and the ORCunit 246 may be a pump 260, while the flow control device within the ORCunit 246 may be a pump 262. In FIG. 2E, the flow control devices usedthroughout the site may be pumps 266A, 266B, 266C, and up to 266N orvariable speed pumps. In FIG. 2F, the flow control devices may includesome combination of one or more control valves 264A, 264B, 264C, and upto 264N and/or one or more pumps 266A, 266B, 266C, and up to 266N. In anembodiment, the one or more flow control devices 254, 256, 248A, 248B,248C, and up to 248N may include one or more of a fixed speed pump, avariable speed drive pump, a control valve, an actuated valve, or othersuitable device to control flow of a fluid.

In FIG. 2G, the drilling rig 200 may include a controller 268 (e.g.,such as the master controller in FIG. 3). The controller 268 may includeinstructions executable by a processor included in the controller 268.The controller 268 may receive various aspects of or data related to thedrilling rig 200, such as temperature, pressure, flow rate, and/or otherfactors from the various sensors disposed or positioned throughout(e.g., sensors 270, 272, 274, 276, 278, 280, 282, 284, 286, 288, 290,292, 294, 296, 297, 298, 299). Based on the aspects or data received,the controller 268 may adjust each of the control valves and/or flowcontrol devices positioned through the drilling rig 200.

In such embodiments, the flow of working fluid to any of the heatexchangers (e.g., heat exchangers 218, 210, 212, and up to 240) may becontrolled via the flow control devices. The controller 268 may utilizethe flow control devices to manage, adjust, or maintain a temperature ofthe flow of drilling fluid, if a flow of drilling fluid flowstherethrough. For example, the total percentage of working fluid flowingto each heat exchanger, for example heat exchangers 218, 210, 212, andup to 240, may initially be equal. As temperatures vary and thetemperature of the flow of drilling fluid rises or falls and/or thetemperature of the engine (based on the temperature of the fluid fromthe water jacket) rises or falls, then the percentage or amount ofworking fluid to a particular heat exchanger may be increased ordecreased to lower or raise, respectively, the temperature of the flowof drilling fluid and/or fluid from the water jacket flowingtherethrough.

For example, the controller 268 may include instructions to optimize ormaximize the amount of electrical power generated. Based on thetemperatures of each fluid received from a heat source and/or thetemperature of working fluid flowing from each heat exchanger, thecontroller 268 may increase (e.g., via control valves or flow controldevices) the amount of working fluid flowing to heat exchangers withhigher temperatures, thus increasing the overall temperature of theworking fluid and thereby generating an increased amount of electricalpower in the ORC unit 246. In another embodiment, the controller 268 mayinclude instructions to increase engine efficiency. In such examples,the controller may increase (e.g., via control valves or flow controldevices) the amount of working fluid flowing to heat exchanger 212associated with the water jacket 206. In yet another embodiment, thecontroller 268 may include instructions to lower the temperature of thedrilling fluid to the lowest potential temperature by increasing theflow of working fluid to the heat exchanger 218 associated with thedrilling fluid borehole return 202. Such working fluid flow rateadjustments may be made or performed intermittently or continuously. Ina further example, an adjustment to a particular working fluid flow ratemay be performed and then temperatures, flow rates, and/or othercharacteristics may be determined. Further adjustments may be performedand temperatures, flow rates, and/or other characteristics may bedetermined again. Such operations may be performed until the temperatureof the flow of gas and/or the working fluid is at a desired temperature,with a selected operating range or window, and/or steady-statetemperature.

In FIG. 2H and as noted, the ORC unit 246 may produce electricity basedon received heated working fluid. The ORC unit 246, in an embodiment,may provide electrical power to battery banks 251 or other energystorage devices, to the grid 253, to a mud chiller 255, and/or to fieldequipment or other equipment/loads 257.

In an embodiment, the site may include a warm supply manifold and a warmreturn manifold, for controlling the flow of warm working fluid fromwarm water heat exchangers (e.g., working fluid from the heat exchangersassociated with the drilling fluid borehole return 202, fluid from thewater jacket 206, and/or fluid from another heat source 238) to a warmfluid intake/outtake of the ORC unit 246. The site may also include ahot supply manifold and a hot return manifold, for controlling the flowof hot working fluid from hot water heat exchangers (e.g., working fluidfrom the heat exchangers associated with the drilling fluid boreholereturn 202, exhaust from the engine exhaust port 204, fluid from thewater jacket 206, and/or fluid from another heat source 238) to a hotfluid intake/outtake of the ORC unit 246.

FIG. 3 is a simplified diagram illustrating a control system formanaging electrical power production at a drilling rig, according to oneor more embodiments of the disclosure. A master controller 302 maymanage the operations of electrical power generation at a facilityduring gas compression. The master controller 302 may be one or morecontrollers, a supervisory controller, programmable logic controller(PLC), a computing device (such as a laptop, desktop computing device,and/or a server), an edge server, a cloud based computing device, and/orother suitable devices. The master controller 302 may be located at ornear the drilling rig. The master controller 302 may be located remotefrom the facility. The master controller 302, as noted, may be more thanone controller. In such cases, the master controller 302 may be locatednear or at the drilling rig, various facilities and/or at other off-sitelocations. The master controller 302 may include a processor 304, or oneor more processors, and memory 306. The memory 306 may includeinstructions. In an example, the memory 306 may be a non-transitorymachine-readable storage medium. As used herein, a “non-transitorymachine-readable storage medium” may be any electronic, magnetic,optical, or other physical storage apparatus to contain or storeinformation such as executable instructions, data, and the like. Forexample, any machine-readable storage medium described herein may be anyof random access memory (RAM), volatile memory, non-volatile memory,flash memory, a storage drive (e.g., hard drive), a solid state drive,any type of storage disc, and the like, or a combination thereof. Asnoted, the memory 306 may store or include instructions executable bythe processor 304. As used herein, a “processor” may include, forexample one processor or multiple processors included in a single deviceor distributed across multiple computing devices. The processor may beat least one of a central processing unit (CPU), a semiconductor-basedmicroprocessor, a graphics processing unit (GPU), a field-programmablegate array (FPGA) to retrieve and execute instructions, a real timeprocessor (RTP), other electronic circuitry suitable for the retrievaland execution instructions stored on a machine-readable storage medium,or a combination thereof.

As used herein, “signal communication” refers to electric communicationsuch as hard wiring two components together or wireless communicationfor remote monitoring and control/operation, as understood by thoseskilled in the art. For example, wireless communication may be Wi-Fi®,Bluetooth®, ZigBee, cellular wireless communication, satellitecommunication, or forms of near field communications. In addition,signal communication may include one or more intermediate controllers orrelays disposed between elements that are in signal communication withone another.

The master controller 302 may include instructions 308 to measure thetemperature at various points at the drilling rig or at the site. Forexample, the temperature at the inlet of one or more heat exchangers maybe measured or sensed from one or more heat exchanger temperaturesensors 320A and up to 320N. In another embodiment, the temperature atthe outlet of one or more heat exchangers may be measured from one ormore heat exchanger temperature sensors 320A and up to 320N. In anotherembodiment, temperature sensors may be positioned at both the inlet andoutlet of the heat exchanger. The master controller 302 may furtherinclude instructions 312 to measure the amount of electrical poweroutput from the ORC unit 330. In an embodiment, the drilling rig or atthe site may include one or more ORC units and, in such examples, eachORC unit may connect to the master controller 302 to provide, amongother information or data, the amount of electrical power output overtime.

The master controller 302 may further connect to one or more heatexchanger valves 326A, 326B, and up to 326N and working fluid valves328A, 328B, and up to 328N. The master controller 302 may includeinstructions 310 to adjust each of these valves based on variousfactors. For example, if the temperature measured from one of the heatexchangers is below a threshold or outside of a selected operatingtemperature range or window and/or if the ambient temperature from theambient temp sensor 322 is above a preselected threshold, then themaster controller 302 may transmit a signal causing one or more of theheat exchanger valves 326A, 326B, up to 362N to close. Such a thresholdmay be defined by the temperature sufficient to ensure the ORC unitgenerates an amount of electrical power. The operating temperature rangeor window may be defined by an operating temperature of the ORC unitand/or by the lowest and highest potential temperature of the flow ofdrilling fluid. The ambient threshold may be defined by an ambienttemperature at which engine performance may degrade and/or drillingfluid may not cool sufficiently. In another example, based on a heatexchanger inlet temperature and an outlet temperature, the mastercontroller 302 may adjust, via a signal transmitted to, one of the oneor more of the heat exchanger valves 326A, 326B, and up to 326N and/orworking fluid valves 328A, 328B, and up to 328N. The master controller302 may consider other factors (e.g., temperature, pressure, flow rate,density, composition, etc.) as described herein.

The master controller 302 may include instructions 306 to measure theworking fluid temperature via a sensor (e.g., via one or more heatexchanger temperature sensors 322). The master controller 302 mayinclude instructions 310 to adjust the flow of working fluid to any oneof the one or more heat exchangers based on the measured temperatures.The flow of the working fluid may be adjusted by the master controller302, as noted, based on various temperature measurements of the workingfluid, via one or more working fluid flow control devices (e.g., workingfluid valves 328A, 328B, up to 328N) and/or a master flow controldevice. In an embodiment, the adjustment of the flow of working fluidmay occur to adjust the temperature of the flow of gas through acorresponding heat exchanger.

As noted, the master controller 302 may adjust the amount of workingfluid flowing to each of the heat exchangers based on an aspect of thedrilling rig to be optimized. For example, adjustment of a working fluidvalve (e.g., working fluid valves 328A, 328B, and/or up to 328N)associated with the drilling fluid may cause a decrease in thetemperature of the drilling fluid to thereby decrease cooling via a mudchiller and to further thereby decrease overall electrical powerutilized at the drilling rig. Adjustment of a second working fluidcontrol valve (e.g., working fluid valves 328A, 328B, and/or up to 328N)may cause an increase in working fluid flow to the heat exchangerassociated with the exhaust output from the engine, thereby causing anincrease in overall electrical power generated by the ORC unit due tothe high heat of the exhaust and to thereby optimize engine andgenerator set performance. Adjustment of a third working fluid flowcontrol device (e.g., working fluid valves 328A, 328B, and/or up to328N) may cause an increase in working fluid flow to the water jacketheat exchanger thereby causing an increase in engine performance due toincreased heat transfer from the engine to the working fluid. Variousadjustments may be made over varying time intervals, the temperatures orother characteristic of the drilling rig to be measured at each intervaland further adjustments made. Finally, the master controller 302 maymaximize each aspect of the drilling rig or maximize one or more aspectbased on other factors. For example, the master controller 302 maymaximize the electrical power generated by the ORC unit during peakhours of electrical power usage of the drilling rig. In other words,when the most electrical power is utilized by equipment at the drillingrig, then the master controller 302 may adjust working fluid controlvalves, such that the most heat is transferred to the working fluidthereby enabling the ORC unit to generate the most electrical power. Inanother example, during off-peak hours, the master controller 302 mayadjust the working fluid to heat exchangers such that enough electricalpower is generated to supply the electrical power requirements duringsuch off-peak hours.

In an embodiment, the master controller 302 may connect to a userinterface 332. A user may interact with the master controller 302 viathe user interface 332. The user may manually enter each of thethresholds, the operating temperature ranges or windows, or some aspectto optimize described herein and/or may manually adjust any of thecontrol valves described herein.

FIG. 4A is a flow diagram of electrical power generation in which,during a drilling operation, working fluid is heated via one or more ofdrilling fluid or drilling mud, engine exhaust, and/or water jacketfluid flow, according to one or more embodiments of the disclosure. Themethod is detailed with reference to the master controller 302 and thedrilling rig 100 of FIGS. 1A through 1C. Unless otherwise specified, theactions of method 400 may be completed within the master controller 302.Specifically, method 400 may be included in one or more programs,protocols, or instructions loaded into the memory of the mastercontroller 302 and executed on the processor or one or more processorsof the master controller 302. The order in which the operations aredescribed is not intended to be construed as a limitation, and anynumber of the described blocks may be combined in any order and/or inparallel to implement the methods.

Turning to FIG. 4A, at block 402, the master controller 302 maydetermine whether a drilling operation is occurring. If a drillingoperation is not occurring, the master controller 402 may wait andperform such a determination may be performed again. If a drillingoperation is occurring or has begun, the master controller 302 mayproceed to perform the next operation.

At block 404, a pump may pump drilling fluid through and around a drillbit thereby cooling the drill bit. The drilling fluid may then flow up aborehole to a drilling fluid return pipe.

At block 406, the master controller 302 may determine or sense atemperature of the drilling fluid, for example, via a drilling fluidreturn temperature sensor. In an embodiment, other aspects of thedrilling fluid or any other fluid may be determined.

At block 408, the master controller 302 may determine whether thetemperature of the drilling fluid is within a range or window. The rangeor window may be defined by a maximum operating temperature of the firstheat exchanger and a minimum temperature at which ORC equipmentgenerates electricity.

At block 410, if the temperature is above or below of a range, themaster controller 302 may determine if the drilling operation isfinished or still occurring. If the temperature is within the range orwindow, the master controller 302 may adjust a divert a drilling fluidto a drilling fluid heat exchanger via a drilling fluid control valve.The drilling fluid control valve may partially or fully divert a portionof the exhaust produced by the engine. In another embodiment, theexhaust control valve may be adjusted to maintain the first heatexchanger. In another embodiment, other aspects may be considered whenadjusting a drilling fluid control valve, such as an amount ofelectrical power generated, temperature of an engine, temperature of anengine's exhaust, temperature of fluid from a water jacket, and so on.In such embodiments, in addition to adjusting the amount of drillingfluid flowing to a heat exchanger, the amount of working fluid flowingto that particular heat exchanger may be adjusted (e.g., an increase inworking fluid causing greater heat transfer from the drilling fluid tothe working fluid and a decrease in working fluid causing lesser heattransfer from the drilling fluid to the working fluid). In other words,the temperature of the drilling fluid may be controlled based on theamount of working fluid flowing through the corresponding heatexchanger.

At block 412, the drilling fluid may be returned to the drilling fluidcontainer from the heat exchanger. At block 414, the master controller302 may determine whether the drilling operation is finished. If thedrilling operation is finished, the master controller 302 may wait untilanother drilling operation begins. If the drilling operation is notfinished, the master controller 302 may perform method 400 again, forthe duration of a drilling operation.

FIGS. 4B and 4C are flow diagrams of electrical power generation inwhich, during drilling operations, working fluid is heated via engineexhaust and/or water jacket fluid flow, according to one or moreembodiment of the disclosure. The method is detailed with reference tothe master controller 302 and drilling rig 100 of FIGS. 1A through 1C.Unless otherwise specified, the actions of method 401 may be completedwithin the master controller 302. Specifically, method 900 may beincluded in one or more programs, protocols, or instructions loaded intothe memory of the master controller 302 and executed on the processor orone or more processors of the master controller 302. The order in whichthe operations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

Turning to FIG. 4B, at block 402, the master controller 302 maydetermine whether a drilling operation is occurring. If a drillingoperation is not occurring, the master controller 402 may wait andperform such a determination may be performed again. If a drillingoperation is occurring or has begun, the master controller 302 mayproceed to perform the next operation.

At block 416, fluid (e.g., exhaust) produced by the engine may betransported to a second heat exchanger. The second heat exchanger mayfacilitate heat transfer from the fluid (e.g., exhaust) to a workingfluid or intermediate work fluid. The heated working fluid orintermediate working fluid may be utilized by an ORC unit to generateelectrical power during an ORC operation. The working fluid orintermediate working fluid may be considered warm or hot and may beutilized in a warm or low temperature ORC operation or a hot or hightemperature ORC operation, respectively.

At block 418, the master controller 302 may sense or determine thetemperature of the exhaust. The master controller 302 may sense ordetermine the temperature of the exhaust via a temperature sensor.

At block 420, the master controller 302 may determine whether thetemperature or thermal mass of the exhaust is within a range or window.The range or window may be defined by a maximum operating temperature orthermal mass of the first heat exchanger and a minimum temperature orthermal mass at which ORC equipment generates electricity.

At block 422, if the temperature or thermal mass is within a range, themaster controller 302 may re-execute or perform method 401 again. If thetemperature or thermal mass is above or below the range or window, themaster controller 302 may adjust an exhaust control valve. The exhaustcontrol valve may partially or fully divert a portion of the exhaustproduced by the engine. In another embodiment, the exhaust control valvemay be adjusted to maintain the second heat exchanger. Over time,scaling or depositions of particulates in the exhaust may build. Assuch, the second heat exchanger may be cleaned or maintained to removethe buildup and, during such cleaning or maintenance, the exhaustcontrol valve may be fully closed. Once the second heat exchanger hasbeen maintained, the exhaust control valve may be adjusted to allow theexhaust to flow to the second heat exchanger. In another embodiment, aportion of the exhaust may be diverted (e.g., via the exhaust controlvalve) from the second heat exchanger to limit the amount of scalingand/or deposition of particulates. In yet another embodiment, theexhaust control valve may be adjusted to prevent interruption ofcatalyst performance.

In another embodiment, the amount of electricity generated may beadjusted based on adjustment of working fluid flowing to the heatexchanger corresponding to the exhaust. Since the exhaust is output fromthe engine at a high temperature, the amount of heat transferred to theworking fluid may be high. However, a temperature of the working fluidmay produce a maximum amount of electrical power. The master controller302 may, based on such data, adjust the working fluid flowing to theheat exchanger corresponding to the exhaust.

Turning to FIG. 4B, at block 402, the master controller 302 maydetermine whether a drilling operation is occurring. If a drillingoperation is not occurring, the master controller 402 may wait andperform such a determination may be performed again. If a drillingoperation is occurring or has begun, the master controller 302 mayproceed to perform the next operation.

At block 424, fluid from a water jacket may be transported to a thirdheat exchanger. The third heat exchanger may facilitate heat transferfrom the fluid of the water jacket to a working fluid or intermediatework fluid. The heated working fluid or intermediate working fluid maybe utilized by an ORC unit to generate electrical power during an ORCoperation. The working fluid or intermediate working fluid may beconsidered warm or hot and may be utilized in a warm or low temperatureORC operation or a hot or high temperature ORC operation, respectively.

At block 426, the master controller 302 may determine whether thetemperature of the fluid from the water jacket is within a range orwindow. The range or window may be defined by a maximum operatingtemperature mass of the third heat exchanger and a minimum temperatureat which ORC equipment generates electricity.

At block 428, if the temperature of the fluid from the water jacket iswithin a range, the master controller 302 may re-execute or performmethod 401 again. If the temperature of the fluid from the water jacketis above or below the range or window, the master controller 302 mayadjust water jacket control valve. The water jacket control valve maypartially or fully divert a portion of the fluid from the water jacket.In another embodiment, the water jacket control valve may be adjusted tomaintain the third heat exchanger. In another embodiment, theperformance of the engine may be maximized based on adjustment ofworking fluid flowing to the heat exchanger corresponding to the fluidfrom the water jacket.

FIG. 5 is a flow diagram of electrical power generation in which, duringa drilling operation, working fluid is heated via one or more fluidsfrom heat sources, according to one or more embodiments of thedisclosure. The method is detailed with reference to the mastercontroller 302 and the drilling rig 100 of FIGS. 1A through 1C. Unlessotherwise specified, the actions of method 500 may be completed withinthe master controller 302. Specifically, method 500 may be included inone or more programs, protocols, or instructions loaded into the memoryof the master controller 302 and executed on the processor or one ormore processors of the master controller 302. The order in which theoperations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

At block 502, the master controller 302 and/or a user may begin adrilling operation. In an embodiment, when a drilling operation begins,the master controller 302 may receive a signal indicating that thedrilling operation has begun. In another embodiment, the activation oruse of pumps, control valves, engines, and/or other drilling rigequipment may indicate to the master controller 302 that a drilling righas begun. In yet another embodiment, a user may indicate that adrilling operation has begun via the user interface 332.

At block 504, the master controller 302 may check or determine, atvarying points during the drilling operation, whether the drillingoperation has finished or has been completed. The master controller 302may, if the drilling operation is ongoing, proceed to the next block inan operation or process (e.g., block 506). In another embodiment, themaster controller 302 may, if the drilling operation has finished or hasbeen completed, proceed back to block 502 and wait until another or anext drilling operation has begun. The master controller 302 maydetermine that a drilling operation is complete if one or more differentequipment at the drilling rig is not being utilized or not operating.For example, if a drilling fluid or mud pump is not operating, themaster controller 302 may determine that the drilling operation hascompleted or has been paused. In another embodiment, a user may indicatethat a drilling operation is complete or paused via the user interface332. In yet another embodiment, the master controller 302 may determinethat a drilling operation is ongoing based on the flow and/or othercharacteristics of various fluids at the drilling rig (e.g., a flow ofdrilling fluid, flow of exhaust, a flow of fluid from an engine water orfluid jacket, temperatures of various fluids, etc.).

At block 506, the master controller 302 or a user may select one or morefluids, each of the fluids corresponding to one or more heat sources ata drilling rig. As noted, a drilling rig may include various sources ofheat. For example, an engine, during operation, may produce heatedexhaust. Further, as the engine operates, the engine's temperature mayincrease. Such a temperature increase may decrease the overall life ofconsumables and/or parts of the engine. To prevent such a decrease, theengine may include a water jacket or fluid jacket (e.g., a jacketutilizing a fluid capable of transporting heat from the engine) to coolthe engine via circulation of water or fluid within the jacket and aheat sink or other cooling equipment. The drilling rig may include otherheat sources, such as heated drilling fluid from a borehole. One or moreof the fluids associated with these various heat sources may each flowthrough added or installed heat exchangers at the site (e.g., a heatexchanger for drilling fluid, one or more heat exchangers correspondingto one or more engines for exhaust, one or more heat exchangerscorresponding to one or more engines for fluid from a fluid jacket,and/or heat exchangers for other sources).

The master controller 302 and/or a user may determine which heat sourceand/or associated or corresponding heat exchanger to utilize for ORCoperations (e.g., selecting a heat source). Such a selection may bebased on the temperature of the fluid flowing from the heat source andwhether the temperature is within an operating range of the ORC unitand/or of a corresponding heat exchanger. The selection may also bebased on flow rates of the fluid and whether the flow rate is sufficientto facilitate heat transfer from the fluid to a working fluid in theassociated or corresponding heat exchanger. For example, the flow ratemay be at such a rate to prevent sufficient heat transfer. The selectionmay be based on the thermal mass of the fluid and whether the thermalmass is within operating range of the associated or corresponding heatexchanger. Other factors may be utilized in such selections, such as adesired, specified, selected, or pre-selected electrical power output;the ambient temperature at the drilling rig; whether engineoptimization, electrical power output maximization, and/or electricalpower utilization (e.g., off-setting equipment power use) is sought; anumber and type of available heat exchangers at the drilling rig; and/oramong other environmental factors at the drilling rig.

In an embodiment, based on the choice of fluid to be utilized for ORCoperations, corresponding heat exchanger valves may be opened or closed.For example, if engine exhaust and fluid from the fluid jacket ischosen, then heat exchanger valves configured to divert fluid fromnormal fluid pathways or pipeline to a corresponding heat exchanger maybe opened (e.g., heat exchanger valves corresponding to fluid pathwaysor pipeline for the exhaust and fluid from the fluid jacket), whileother heat exchanger valves may be closed (e.g., a heat exchanger valvecorresponding to the fluid pathway or pipeline for the drilling fluid).The heat exchanger valves may be opened or closed based on signalstransmitted via the master controller 302 or manually by a user. Othervarious combinations of heat sources may be selected.

For example, if a user or if the master controller 302 selects one ormore fluids based on electrical power utilization, then the mastercontroller 302 may select the drilling fluid, in addition to engineexhaust and/or fluid from a fluid jacket. In such examples, the drillingfluid may be cooled to a specified or preselected temperature via acorresponding heat exchanger and then further cooled via a mud chiller.The mud chiller may utilize electrical power, thus, to ensure electricalpower utilization is optimized, the amount of working fluid flowing tothe heat exchanger corresponding to the drilling fluid may be increased,the amount of drilling fluid flowing through the heat exchanger may beincreased, and/or the electrical power generated by the ORC unit may bedirected to or utilized by the mud chiller.

In another example, if a user or if the master controller 302 selectsone or more fluids based on engine optimization or performance, then themaster controller 302 may select the fluid from the fluid jacket, aswell as, in some embodiments, to engine exhaust. In such examples, toensure that the engine operates efficiently, the fluid from the fluidjacket may pass through a corresponding heat exchanger and the workingfluid flowing to that heat exchanger may be increased, thus cooling thefluid in the fluid jacket to a lower than typical temperature. Afterpassing through the heat exchanger the fluid in the fluid jacket maypass through a heat sink or other cooler typically used in suchcomponents thereby further cooling the fluid. The cooled fluid may thenflow to the fluid jacket and cool the engine. The engine may be cooledmore than typical due to the lower temperature fluid in the fluidjacket. Exhaust may be utilized to generate additional electrical power(e.g., additional to the electrical power generated via the fluid in thefluid jacket). The additional electrical power may be utilized byequipment at the drilling rig, thus allowing the engine to operate atlower speeds or operate for a reduced time thereby reducing engine wear,extending or increasing engine life, and/or extending or increasinggenerator set life.

In another example, if a user or if the master controller 302 selectsone or more fluids based on electrical power generated, then the mastercontroller 302 may select the exhaust from the engine, as well any otherheat source. Since exhaust typically has a high thermal mass andtemperature, the exhaust may be utilized to generate substantial amountsof electrical power. Any other heat source selected may be based on thetemperature of the heat source (e.g., higher temperature heat sourcesbeing selected first).

In another example, if a user or if the master controller 302 selectsone or more fluids based on drilling fluid temperature, then the mastercontroller 302 may select the drilling fluid, as well as engine exhaustand/or fluid from a fluid jacket. In such examples, the drilling fluidmay be cooled to a specified or preselected temperature via acorresponding heat exchanger and then further cooled via a mud chiller.The cooled drilling fluid may ensure that bottom-hole assemblycomponents operate longer (e.g., extending the life span of thecomponents).

At block 508, the master controller 302 may sense an ambient temperatureat a drilling rig. One or more ambient temperature sensors may bepositioned at various points throughout the drilling rig. For example,an ambient temperature sensor may be positioned proximate to or nearbythe engine. Another ambient temperature sensor may be positioned at apreselected distance from the engine and/or at a location where heat isnot generated to thereby produce an actual ambient temperature of theenvironment or atmosphere at the drilling rig. Other ambient temperaturesensors may be positioned throughout the drilling rig. Each of the oneor more ambient temperature sensors may provide a signal to the mastercontroller 302. The signal may indicate the temperature at the locationwhere the ambient temperature is disposed or positioned.

At block 510, the master controller 302 may sense the temperature ofeach selected fluid. In such examples, temperature sensors may bepositioned nearby, within, or proximate to a pipeline, conduit, or fluidpath corresponding to the selected fluid. The temperature sensor may bepositioned upstream of the heat exchanger (e.g., prior to where theselected fluid enters the heat exchanger). The master controller 302 mayutilize temperature or other characteristics or aspects of the selectedfluid from other sensors positioned throughout the drilling rig, such astemperature sensors positioned downstream of the heat exchangers, flowmeters positioned upstream and/or downstream of the heat exchangers,pressure sensors or transducers positioned upstream and/or downstream ofthe heat exchangers, and/or other sensors positioned throughout thedrilling rig.

At block 512, the master controller 302 may sense the temperature ofworking fluid associated with each of the selected fluids. In suchexamples, temperature sensors may be positioned nearby, within, orproximate to a pipeline, conduit, or fluid path corresponding to workingfluid associate with or corresponding to a selected fluid. Thetemperature sensor may be positioned upstream or downstream of the heatexchanger (e.g., prior to where the working fluid enters the heatexchanger or subsequent to where the working fluid exits the heatexchanger). The master controller 302 may utilize temperature or otheraspects or characteristics of the working fluid from other sensorspositioned throughout the drilling rig, such as flow meters positionedupstream and/or downstream of the heat exchangers, pressure sensors ortransducers positioned upstream and/or downstream of the heatexchangers, and/or other sensors positioned throughout the drilling rig.

At block 514, the master controller 302 may determine an amountelectrical power utilized. In an embodiment, one or more ORC units maybe positioned at the drilling rig. The ORC units may be configured togenerate a range of electrical power. The upper range or maximum amountof electrical power of the ORC unit may be known or may be provided tothe master controller 302. Further, the master controller 302 may be insignal communication with each component or equipment at the drillingrig that utilizes electrical power. The master controller 302 maydetermine the amount of electrical power utilized by each of thecomponents or equipment. As such, the master controller 302 maydetermine the total amount of electrical power utilized at the drillingrig at an any particular time interval or on an ongoing basis.

At block 516, the master controller 302 may determine whether anyselected fluid is outside a specified operating range. The operatingrange may be defined by the operating temperature of the correspondingheat exchanger (e.g., the highest temperature which a heat exchanger maybe able to withstand and/or the lowest temperature at which heattransfer to a working fluid is facilitated) and/or the ORC unit (e.g.,the temperature of fluid at which the ORC unit generates electricalpower or the maximum amount of electrical power). The operating rangemay include or may be defined by temperatures to optimize variousaspects of electrical power generation and/or engine performance at thedrilling rig. For example, the fluid selected (e.g., at block 506) maybe based on optimizing a certain aspect, such as engine optimization orperformance, electrical power generated, drilling fluid temperature,and/or electrical power utilization (e.g., off-setting electrical poweruse at the drilling rig). If any of the selected fluids are outside ofthe specified operating range, then the method 500 may proceed to block524, otherwise the method 500 may proceed to block 518.

At block 518, the master controller 302 may determine whether theambient temperature exceeds a threshold. The threshold may be defined bya temperature at which an engine's performance degrades and/or atemperature at which drilling fluid may not be cooled sufficiently. Ifthe ambient temperature exceeds the threshold, then the method 500 mayproceed to block 524, otherwise the method 500 may proceed to block 520.

At block 520, the master controller 302 may determine whether theelectrical power utilized at the drilling rig exceeds a threshold. Thethreshold may be defined by the maximum amount of electrical powergenerated by the ORC unit. The threshold may be defined by an arbitraryamount of electrical power or by the maximum amount of electrical powergenerated by the ORC unit plus an amount of electrical power utilized oran amount of electrical power allowable from a fossil fuel basedgenerator set. If the electrical power utilized exceeds the threshold,then the method 500 may proceed to block 524, otherwise the method 500may proceed to block 522.

At block 522, the master controller 302 may determine whether theworking fluid for each selected fluid is within an operating range. Theoperating range may be defined by a temperature of working fluid atwhich an ORC unit generates electrical power and a temperature ofworking fluid at which the ORC unit generates a maximum amount ofelectrical power. If the working fluid is within the operating range,then the method 500 may proceed to block 504, otherwise the method 500may proceed to block 524.

At block 524, the master controller 302 may adjust each working fluidflow control device associated with each selected fluid. The workingfluid flow control device may control an amount of working fluid flowingto a heat exchanger. The adjustment of the position of each workingfluid flow control device may be based on the various temperaturesand/other aspects, as well as whether an aspect exceeds a thresholdand/or is within an operating range. For example, if the working fluidassociated with a heat exchanger corresponding to drilling fluid islower than the smallest value of the operating range of the ORC unit,then the corresponding working fluid flow control device may be closed.In such an example and in other examples, an increase in working fluidflowing to a heat exchanger may increase facilitation of heat from afluid to the working fluid, while a decrease in working fluid flowing toa heat exchanger may decrease the facilitation of heat from a fluid tothe working fluid.

At block 526, the master controller 302 may adjust each heat exchangervalve associated with each selected fluid. The valve associated with aspecified heat exchanger may control the amount of a selected fluidflowing to a heat exchanger. The adjustment of the position of eachvalve may be based on the various temperatures and/other aspects, aswell as whether an aspect exceeds a threshold and/or is within anoperating range. For example, if the selected fluid associated with aheat exchanger is lower than the least value of the operating range ofthe ORC unit, then the corresponding valve may be closed. In such anexample and in other examples, an increase in a selected fluid flowingto a heat exchanger may increase facilitation of heat transfer from theselected fluid to the working fluid, while a decrease in selected fluidflowing to the heat exchanger may decrease the facilitation of heat fromthe selected fluid to the working fluid.

In an embodiment, after all adjustments are made the method 500 may beperformed again or until the drilling operation has finished. Further,the master controller 302 may wait a preselected interval of timebetween each sensing or measurement of temperature and/or other aspectsor characteristics and adjustment. The preselected interval of time maybe sufficient to allow temperatures to stabilize (e.g., afteradjustment, temperatures may vary due to such adjustments, thus themaster controller 302 may wait until temperatures and/or other aspectsare stabilized). The preselected interval of time may be about 30seconds, about 1 minute, about 5 minutes, about 15 minutes, about 30minutes, or longer.

FIG. 6 is a flow diagram of electrical power generation in which, duringa drilling operation, working fluid is heated via one or more fluidsfrom heat sources, according to one or more embodiments of thedisclosure. The method is detailed with reference to the mastercontroller 302 and the drilling rig 100 of FIGS. 1A through 1C. Unlessotherwise specified, the actions of method 600 may be completed withinthe master controller 302. Specifically, method 600 may be included inone or more programs, protocols, or instructions loaded into the memoryof the master controller 302 and executed on the processor or one ormore processors of the master controller 302. The order in which theoperations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

At block 602, the master controller 302 and/or a user may begin adrilling operation. In an embodiment, when a drilling operation begins,the master controller 302 may receive a signal indicating that thedrilling operation has begun. In another embodiment, the activation oruse of pumps, control valves, engines, and/or other drilling rigequipment may indicate to the master controller 302 that a drilling righas begun. In yet another embodiment, a user may indicate that adrilling operation has begun via the user interface 332.

At block 604, the master controller 302 may check or determine, atvarying points during the drilling operation, whether the drillingoperation has finished or has been completed. The master controller 302may, if the drilling operation is ongoing, proceed to the next block inan operation or process (e.g., block 506). In another embodiment, themaster controller 302 may, if the drilling operation has finished or hasbeen completed, proceed back to block 502 and wait until another or anext drilling operation has begun. The master controller 302 maydetermine that a drilling operation is complete if one or more differentequipment at the drilling rig is not being utilized or not operating.For example, if a drilling fluid or mud pump is not operating, themaster controller 302 may determine that the drilling operation hascompleted or has been paused. In another embodiment, a user may indicatethat a drilling operation is complete or paused via the user interface332. In yet another embodiment, the master controller 302 may determinethat a drilling operation is ongoing based on the flow of various fluidsat the drilling rig (e.g., a flow of drilling fluid, exhaust, fluid froman engine water or fluid jacket, etc.).

At block 606, the master controller 302 may sense a drilling fluidtemperature. In such an embodiment, a temperature sensor may bepositioned along a drilling fluid return pipeline. The temperaturesensor may provide a signal to the master controller 302 indicating thetemperature of the drilling fluid.

At block 608, the master controller 302 may sense an ambient temperatureat a drilling rig. One or more ambient temperature sensors may bepositioned at various points throughout the drilling rig. For example,an ambient temperature sensor may be positioned proximate to or nearbythe engine. Another ambient temperature sensor may be positioned at apreselected distance from the engine and/or at a location where heat isnot generated to thereby produce an actual ambient temperature of theenvironment or atmosphere at the drilling rig. Other ambient temperaturesensors may be positioned throughout the drilling rig. Each of the oneor more ambient temperature sensors may provide a signal to the mastercontroller 302. The signal may indicate the temperature at the locationwhere the ambient temperature is disposed or positioned.

At block 610, the master controller 302 may determine an amountelectrical power utilized at the drilling rig. In an embodiment, one ormore ORC units may be positioned at the drilling rig. The ORC units maybe configured to generate a range of electrical power. The upper rangeor maximum amount of electrical power of the ORC unit may be known ormay be provided to the master controller 302. Further, the mastercontroller 302 may be in signal communication with each component orequipment at the drilling rig that utilizes electrical power. The mastercontroller 302 may determine the amount of electrical power utilized byeach of the components or equipment. As such, the master controller 302may determine the total amount of electrical power utilized at thedrilling rig at an any particular time interval or on an ongoing basis.In another embodiment, in addition to or rather than the determinationof electrical power utilized, the master controller 302 may determine anamount of electrical power generated by a generator set.

At block 612, may sense a working fluid temperature associated withdrilling fluid. In such an embodiment, a temperature sensor may bepositioned proximate to an outlet where working fluid exits the heatexchanger. An additional temperature sensor may be positioned at aninlet where working fluid enters the heat exchanger. The temperaturesensors may provide signals to the master controller 302 indicating thetemperature of the working fluid.

At block 614, may sense a working fluid temperature associated withexhaust. In such an embodiment, a temperature sensor may be positionedproximate to an outlet where working fluid exits the heat exchanger. Anadditional temperature sensor may be positioned at an inlet whereworking fluid enters the heat exchanger. The temperature sensors mayprovide signals to the master controller 302 indicating the temperatureof the working fluid.

At block 616, may sense a working fluid temperature associated withfluid from the fluid jacket. In such an embodiment, a temperature sensormay be positioned proximate to an outlet where working fluid exits theheat exchanger. An additional temperature sensor may be positioned at aninlet where working fluid enters the heat exchanger.

In an embodiment, additional temperature sensors and/or other types ofsensors may be included or positioned throughout the drilling rig. Forexample, the temperature of the exhaust and/or the fluid from the fluidjacket may be sensed prior to entry into or after exit from the heatexchanger.

At block 618, the master controller 302 may determine whether thedrilling fluid is outside an operating range. The operating range may bedefined by a temperature at which heat transferred to working fluid maycause the ORC unit to generate electrical power. Other temperatures ofother fluids (e.g., exhaust and/or fluid from the fluid jacket) may beconsidered. If the temperature of the drilling fluid is outside of thespecified operating range, then the method 600 may proceed to block 620,otherwise the method 600 may proceed to block 626.

At block 620, the master controller 302 may determine whether theambient temperature exceeds a threshold. The threshold may be defined bya temperature at which an engine's performance degrades and/or atemperature at which drilling fluid may not be cooled sufficiently. Ifthe ambient temperature exceeds the threshold, then the method 600 mayproceed to block 622, otherwise the method 600 may proceed to block 626.

At block 622, the master controller 302 may determine whether theelectrical power utilized at the drilling rig exceeds a threshold. Thethreshold may be defined by the maximum amount of electrical powergenerated by the ORC unit. The threshold may be defined by an arbitraryamount of electrical power (e.g., the amount set by a user or the mastercontroller 302) or by the maximum amount of electrical power generatedby the ORC unit plus an amount of electrical power utilized or an amountof electrical power allowable from a fossil fuel based generator set. Ifthe electrical power utilized exceeds the threshold, then the method 500may proceed to block 524, otherwise the method 500 may proceed to block522.

At block 624, the master controller 302 may determine whether theworking fluid for each heat source (e.g., the drilling fluid, theexhaust, and/or the fluid from a fluid jacket) is within an operatingrange. The operating range may be defined by a temperature of workingfluid at which an ORC unit generates electrical power and a temperatureof working fluid at which the ORC unit generates a maximum amount ofelectrical power. If the working fluid is within the operating range,then the method 600 may proceed to block 604, otherwise the method 600may proceed to block 626.

At block 626, the master controller 302 may adjust the amount of workingfluid flowing to the heat exchanger associated with the drilling fluidand/or the amount of drilling fluid flowing to the heat exchanger. Byadjusting the amount of working fluid and drilling fluid flowing throughthe heat exchanger, the temperature of the working fluid and/or thedrilling fluid may be controlled. Such adjustments may occur based onwhich block of the method precedes block 626. For example, if thetemperature of the drilling fluid is outside of the operating range,such as at a temperature to not sufficiently transfer heat to workingfluid to generate electrical power in the ORC unit, then the workingfluid flow and the drilling fluid to the heat exchanger may be prevented(e.g., corresponding valves closed).

At block 628, the master controller 302 may adjust the amount of workingfluid flowing to the heat exchanger associated with the fluid from thefluid jacket and/or the amount of fluid from the fluid jacket flowing tothe heat exchanger. By adjusting the amount of working fluid and fluidfrom the fluid jacket flowing through the heat exchanger, thetemperature of the fluid from the fluid jacket and/or the working fluidmay be controlled. For example, if engine performance is prioritized andambient temperature is above a threshold, then working fluid flow to theheat exchanger associated with fluid from the fluid jacket may beincreased to thereby further cool the fluid from the fluid jacket.

At block 630, the master controller 302 may adjust the amount of workingfluid flowing to the heat exchanger associated with the exhaust and/orthe amount of exhaust flowing to the heat exchanger. By adjusting theamount of working fluid and exhaust flowing through the heat exchanger,the temperature of the working fluid may be controlled. For example, ifelectrical power generation is prioritized, after checking electricalpower utilization and generation, working fluid flow to the heatexchanger associated with exhaust may be increased, thereby increasingthe temperature of the working fluid and increasing electrical poweroutput by the ORC unit. The master controller 302 may, after adjustment,perform method 600 until the drilling operation is finished.

This application is a non-provisional of and claims priority to and thebenefit of U.S. Provisional Application No. 63/269,862, filed Mar. 24,2022, titled “Systems and Methods for Generation of Electrical Power ata Drilling Rig,” and U.S. Provisional Application No. 63/269,572, filedMar. 18, 2022, titled “Systems and Methods for Generation of ElectricalPower at a Drilling Rig,” U.S. Provisional Application No. 63/261,601,filed Sep. 24, 2021, titled “Systems and Methods Utilizing GasTemperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. This application also is a continuation-in-part ofU.S. Non-Provisional application Ser. No. 17/305,297, filed Jul. 2,2021, titled “Systems for Generating Geothermal Power in an OrganicRankine Cycle Operation During Hydrocarbon Production Based on WorkingFluid Temperature,” which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties. This application further is acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/578,520, filed Jan. 19, 2022, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” which claims priority to and thebenefit of U.S. Provisional Application No. 63/261,601, filed Sep. 24,2021, titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” and U.S. Provisional Application No. 63/200,908, filed Apr. 2,2021, titled “Systems and Methods for Generating Geothermal Power DuringHydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationalso further is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/578,528, filed Jan. 19, 2022, titled “Systemsand Methods Utilizing Gas Temperature as a Power Source,” which claimspriority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. The application still further is acontinuation-in-part of U.S. Non-Provisional application Ser. No.17/578,542, filed Jan. 19, 2022, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” which claims priority to and thebenefit of U.S. Provisional Application No. 63/261,601, filed Sep. 24,2021, titled “Systems and Methods Utilizing Gas Temperature as a PowerSource,” and U.S. Provisional Application No. 63/200,908, filed Apr. 2,2021, titled “Systems and Methods for Generating Geothermal Power DuringHydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationadditionally is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/578,550, filed Jan. 19, 2022, titled “Systemsand Methods Utilizing Gas Temperature as a Power Source,” which claimspriority to and the benefit of U.S. Provisional Application No.63/261,601, filed Sep. 24, 2021, titled “Systems and Methods UtilizingGas Temperature as a Power Source,” and U.S. Provisional Application No.63/200,908, filed Apr. 2, 2021, titled “Systems and Methods forGenerating Geothermal Power During Hydrocarbon Production,” thedisclosures of all of which are incorporated herein by reference intheir entireties. The application is also a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/650,811, filed Feb. 11, 2022,titled “Systems for Generating Geothermal Power in an Organic RankineCycle Operation During Hydrocarbon Production Based on Wellhead FluidTemperature,” which is a continuation of U.S. Non-Provisionalapplication Ser. No. 17/305,298, filed Jul. 2, 2021, titled “Controllerfor Controlling Generation of Geothermal Power in an Organic RankineCycle Operation During Hydrocarbon Production,” now U.S. Pat. No.11,280,322, issued Mar. 22, 2022, which claims priority to and thebenefit of U.S. Provisional Application No. 63/200,908, filed Apr. 2,2021, titled “Systems and Methods for Generating Geothermal Power DuringHydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationfurther still is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/670,827, filed Feb. 14, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” which is a continuation-in-part of U.S.Non-Provisional application Ser. No. 17/305,296, filed Jul. 2, 2021,titled “Controller for Controlling Generation of Geothermal Power in anOrganic Rankine Cycle Operation During Hydrocarbon Production,” now U.S.Pat. No. 11,255,315, issued Feb. 22, 2022, which claims priority to andthe benefit of U.S. Provisional Application No. 63/200,908, filed Apr.2, 2021, titled “Systems and Methods for Generating Geothermal PowerDuring Hydrocarbon Production,” the disclosures of all of which areincorporated herein by reference in their entireties. This applicationyet further is a continuation-in-part of U.S. Non-Provisionalapplication Ser. No. 17/682,126, filed Feb. 28, 2022, titled “Systemsand Methods for Generation of Electrical Power in an Organic RankineCycle Operation,” which is a continuation of U.S. Non-Provisionalapplication Ser. No. 17/494,936, filed Oct. 6, 2021, titled “Systems andMethods for Generation of Electrical Power in an Organic Rankine CycleOperation,” now U.S. Pat. No. 11,293,414, issued Apr. 5, 2022, which isa continuation-in-part of U.S. Non-Provisional application Ser. No.17/305,296, filed Jul. 2, 2021, titled “Controller for ControllingGeneration of Geothermal Power in an Organic Rankine Cycle OperationDuring Hydrocarbon Production,” now U.S. Pat. No. 11,255,315, issuedFeb. 22, 2022, which claims priority to and the benefit of U.S.Provisional Application No. 63/200,908, filed Apr. 2, 2021, titled“Systems and Methods for Generating Geothermal Power During HydrocarbonProduction,” the disclosures of all of which are incorporated herein byreference in their entireties.

In the drawings and specification, several embodiments of systems andmethods to provide electrical power from heat of a flow of gas and/orother source have been disclosed, and although specific terms areemployed, the terms are used in a descriptive sense only and not forpurposes of limitation. Embodiments of systems and methods have beendescribed in considerable detail with specific reference to theillustrated embodiments. However, it will be apparent that variousmodifications and changes can be made within the spirit and scope of theembodiments of systems and methods as described in the foregoingspecification, and such modifications and changes are to be consideredequivalents and part of this disclosure.

What is claimed is:
 1. A method for increasing one or more of engine,generator set, or bottom-hole assembly performance and lifespan, themethod comprising: during a drilling operation: sensing, via a drillingfluid return pipe sensor, a temperature of a flow of drilling fluid froma borehole; sensing, via an ambient temperature sensor, an ambienttemperature of a drilling rig; determining electrical power utilized bydrilling rig equipment and generated by a generator set driven by anengine; in response to one or more of (a) the temperature of the flow ofdrilling fluid from the borehole exceeding an operating range, (b) theambient temperature exceeding an ambient temperature threshold, or (c)the electrical power utilized by the drilling rig equipment exceeding apower requirement threshold: adjusting one or more of (1) a firstworking fluid flow control device, the first working fluid flow controldevice to control a flow of working fluid to a drilling fluid heatexchanger, the drilling fluid heat exchanger configured to transfer heatfrom the drilling fluid to the flow of the working fluid, thetransferred heat to cause a power generation unit to generate electricalpower, (2) a second working fluid flow control device, the secondworking fluid flow control device to control a flow of working fluid toan exhaust heat exchanger, the exhaust fluid heat exchanger configuredto transfer heat from exhaust generated by the engine to the flow of theworking fluid, the transferred heat to cause a power generation unit togenerate electrical power, or (3) a third working fluid flow controldevice, the third working fluid flow control device to control a flow ofworking fluid to a fluid jacket heat exchanger, the fluid jacket fluidheat exchanger configured to transfer heat from the fluid of the fluidjacket to the flow of the working fluid, the fluid jacket configured tocool the engine, the transferred heat to cause a power generation unitto generate electrical power.
 2. The method of claim 1, whereinadjustment of the first working fluid flow control device to cause anincrease in working fluid flow to the drilling fluid heat exchangercauses a decrease in the temperature in drilling fluid to therebydecrease cooling via a mud chiller and to further thereby decreaseoverall electrical power utilized at the drilling rig.
 3. The method ofclaim 2, the power generation unit comprises an Organic Rankine Cycle(ORC) unit, and wherein adjustment of the second working fluid flowcontrol device to cause an increase in working fluid flow to the exhaustheat exchanger causes an increase in overall electrical power generatedby the ORC unit due to the high heat of the exhaust and to therebyoptimize engine and generator set performance.
 4. The method of claim 1,wherein the fluid jacket comprises a water jacket, wherein the fluidjacket heat exchanger comprises a water jacket heat exchanger, andwherein adjustment of the third working fluid flow control device tocause an increase in working fluid flow to the water jacket heatexchanger causes an increase in engine performance due to increased heattransfer from the engine to the working fluid.
 5. A method forgenerating power in an organic Rankine cycle (ORC) operation in thevicinity of a drilling rig, the method comprising: operating a drillingrig to form a borehole in a subsurface formation; during operation ofthe drilling rig, selecting one or more fluids from one or morecorresponding heat sources, the one or more fluids selected to flow toone or more corresponding heat exchangers, each of the one or morecorresponding heat exchangers positioned to transfer heat from theheated drilling fluid to a flow of a working fluid to generate a heatedworking fluid, the heated working fluid to cause an ORC unit to generateelectrical power.
 6. The method of claim 5, wherein the one or more heatsources include exhaust produced by one of one or more enginespositioned in the vicinity of the drilling rig or fluid from a fluidjacket corresponding to one of the one or more engines.
 7. The method ofclaim 5, wherein the one or more heat sources include drilling fluidutilized during operation of the drilling rig, and wherein one or moreof the one or more heat sources are selected based on temperature offluid from each of the one or more heat sources.
 8. The method of claim5, wherein the one or more of the one or more heat sources are selectedbased on the ambient temperature at the drilling rig.
 9. The method ofclaim 5, wherein one or more of the one or more heat sources areselected based on one or more of engine optimization, electrical poweroutput maximization, or electrical power utilization at the drillingrig.
 10. A method for generating power in an organic Rankine cycle (ORC)operation in the vicinity of a drilling rig, the method comprising:during a drilling operation: selecting, based on one or more of (a)engine optimization, (b) electrical power output maximization, or (c)electrical power utilization at the drilling rig, diversion of an amountof one or more of (1) engine exhaust, via a first heat exchanger supplyvalve, from an engine exhaust conduit to a first heat exchanger and (2)fluid, via a second heat exchanger supply valve, from an engine fluidjacket to a second heat exchanger, each of the first heat exchanger andthe second heat the heat exchanger positioned to transfer heat from theengine exhaust and fluid to a flow of a working fluid to generate aheated working fluid, the heated working fluid to cause an ORC unit togenerate electrical power.
 11. The method of claim 10, wherein selectionof diversion the amount of one or more engine exhaust and fluid isfurther based on ambient temperature at the drilling rig, temperature ofthe engine exhaust, temperature of the fluid, temperature of workingfluid corresponding to the engine exhaust, and temperature of workingfluid corresponding to the fluid.
 12. A method for increasing one ormore of engine, generator set, or bottom-hole assembly performance andlifespan, the method comprising: while a drilling operation occurs:sensing, via an ambient temperature sensor, an ambient temperature of adrilling rig; determining electrical power utilized by drilling rigequipment and generated by a generator set driven by an engine; inresponse to one or more of (a) t er utilized by the drilling rigequipment exceeding a power requirement threshold: adjusting one or moreof (1) a first working fluid flow control device, the first workingfluid flow control device to control a flow of working fluid to anexhaust heat exchanger, the exhaust fluid heat exchanger configured totransfer heat from exhaust generated by the engine to the flow of theworking fluid, the transferred heat to cause a power generation unit togenerate electrical power, or (2) a second working fluid flow controldevice, the second working fluid flow control device to control a flowof working fluid to a fluid jacket heat exchanger, the fluid jacketfluid heat exchanger configured to transfer heat from the fluid of thefluid jacket to the flow of the working fluid, the fluid jacketconfigured to cool the engine, the transferred heat to cause a powergeneration unit to generate electrical power.
 13. The method of claim12, wherein adjustment of the first working fluid flow control device tocause an increase in working fluid flow to the drilling fluid heatexchanger causes a decrease in the temperature in drilling fluid tothereby decrease cooling via a mud chiller and to further therebydecrease overall electrical power utilized at the drilling rig, whereinthe power generation unit comprises an Organic Rankine Cycle (ORC) unit,wherein adjustment of the first working fluid flow control device causesan increase in working fluid flow to the exhaust heat exchanger tothereby increase overall electrical power generated by the ORC unit dueto the high heat of the exhaust, wherein the fluid jacket comprises awater jacket, wherein the fluid jacket heat exchanger comprises a waterjacket heat exchanger, and wherein adjustment of the second workingfluid flow control device to cause an increase in working fluid flow tothe water jacket heat exchanger causes an increase in engine performancedue to increased heat transfer from the engine to the working fluid.